Electroacoustic conversion film web, electroacoustic conversion film, and method of manufacturing an electroacoustic conversion film web

ABSTRACT

Provided are an electroacoustic conversion film web, an electroacoustic conversion film, and a method of manufacturing an electroacoustic conversion film web in which costs can be reduced by reducing the number of operations without damage to thin film electrodes, the points of electrode lead-out portions can be freely determined, and thus high productivity can be achieved. A preparation step of preparing an electrode laminated body in which a single thin film electrode and a single protective layer are laminated and a lamination step of laminating the electrode laminated body and an piezoelectric layer are included. A non-adhered portion that is not adhered to the piezoelectric layer is provided in at least one end portion of the thin film electrode in a case where the electrode laminated body and the piezoelectric layer are laminated in the lamination step.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of PCT International Application No.PCT/JP2016/063883 filed on May 10, 2016, which claims priority under 35U.S.C. § 119(a) to Japanese Patent Application No. 2015-096470 filed onMay 11, 2015. The above application is hereby expressly incorporated byreference, in its entirety, into the present application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an electroacoustic conversion film webwhich is processed to be used as an electroacoustic conversion film usedfor an acoustic device such as a speaker or a microphone, anelectroacoustic conversion film, and manufacturing methods thereof.

2. Description of the Related Art

In response to thinning of displays such as liquid crystal displays andorganic electroluminescence (EL) displays, speakers used in such thindisplays are also required to be lighter and thinner. As such alightweight and thin speaker, it is considered to adopt a sheet-likepiezoelectric film having a property that stretches and contracts inresponse to an applied voltage.

For example, in JP2008-294493A, it is described that a piezoelectricfilm obtained by performing polarization processing with respect to amonoaxially stretched film of polyvinylidene fluoride (PVDF) at a highvoltage is used.

In order to adopt the piezoelectric film as a speaker, it is necessarythat a stretching and contracting movement along a film surface isconverted into a vibration of the film surface. This conversion from thestretching and contracting movement into the vibration is attained byholding the periphery of the piezoelectric film in a bent state, andthus the piezoelectric film is able to function as a speaker.

Here, the present applicants suggested, as a piezoelectric film capableof being used for a thin speaker, an electroacoustic conversion filmincluding a polymer composite piezoelectric body in which piezoelectricbody particles are dispersed in a viscoelastic matrix formed of apolymer material having viscoelasticity at a normal temperature, thinfilm electrodes formed on both surfaces of the polymer compositepiezoelectric body, and protective layers formed on the surfaces of thethin film electrodes, which is disclosed in JP2014-14063A.

In such a piezoelectric film, two thin film electrodes forming anelectrode pair for applying a voltage to a piezoelectric layer areformed on both surfaces of the piezoelectric layer that stretches andcontracts in response to an applied voltage, and wires need to beconnected to the two thin film electrodes.

On the other hand, the piezoelectric film used as a thin speaker alsoneeds to be thinner from viewpoints of not only thinning of the speakerbut also responsiveness and widening of a reproducible band. However, ina thin electrode layer such as a vapor-deposited film, it is difficultto connect wires by soldering or the like.

In addition, connection of wires to the thin film electrodes needs to beperformed while insulation between the thin film electrodes on bothsurfaces of the piezoelectric layer is ensured. However, the connectionof wires is not easy because the thickness of the piezoelectric layer isas thin as approximately tens of vim.

Regarding this, in JP2014-209724A, the applicant proposed anelectroacoustic conversion film having a configuration in which thinfilm electrodes and protective layers have electrode lead-out portionsprotruding in a convex shape, in the outer portions of a piezoelectriclayer in a surface direction. With this configuration, electrodes can bedrawn from the thin film electrodes and connection of wires by solderingcan be easily performed. Furthermore, drawing of the electrodes can beperformed while insulation between the thin film electrodes on bothsurfaces is ensured.

SUMMARY OF THE INVENTION

In JP2014-209724A, as a method of preparing the electroacousticconversion film having a configuration in which the thin film electrodesand the protective layers have the electrode lead-out portionsprotruding in a convex shape, in the outer portions of the piezoelectriclayer in the surface direction, a method of providing the electrodelead-out portions protruding in a convex shape by entirely laminatingthe piezoelectric layer, the thin film electrodes, and the protectivelayers, rubbing the piezoelectric layer with a cotton swab or the likeimpregnated with a solvent, and dissolving and removing a portion of thepiezoelectric layer is described.

However, in the method of laminating the piezoelectric layer, the thinfilm electrodes, and the protective layers and dissolving and removingthe portion of the piezoelectric layer that is to become the electrodelead-out portion, there is concern that the thin film electrodes may bedamaged, for example, the thin film electrodes may be dissolved. Inaddition, there are problems that the number of operations increases,the investment in facilities increases, and costs increase.

In addition, since the electrode lead-out portion is formed in a shapeprotruding in a convex shape, it is necessary that the position of theelectrode lead-out portion is determined in advance in a case where anelectroacoustic conversion film is prepared, and the position of theelectrode lead-out portion cannot be changed after the preparation.Therefore, in a case where various shapes of electroacoustic conversionfilms in which the positions, shapes, and the like of electrode lead-outportions vary are prepared, it is necessary that preparation conditionsin a step of forming the electrode lead-out portion are changed for eachof the electroacoustic conversion films, and there is a problem thatproductivity cannot be increased.

An object of the present invention is to solve such a problem of therelated art, and is to provide an electroacoustic conversion film web,an electroacoustic conversion film, a manufacturing method of anelectroacoustic conversion film web, and a manufacturing method of anelectroacoustic conversion film, in which costs can be reduced byreducing the number of operations without damage to thin filmelectrodes, the points of electrode lead-out portions can be freelydetermined, and thus high productivity can be achieved.

In order to attain the object, the present inventors found that byproviding a preparation step of preparing an electrode laminated body inwhich a single thin film electrode and a single protective layer arelaminated and a lamination step of laminating the electrode laminatedbody and an piezoelectric layer, and providing a non-adhered portionthat is not adhered to the piezoelectric layer, in at least one endportion of the thin film electrode in a case where the electrodelaminated body and the piezoelectric layer are laminated in thelamination step, the object can be attained, and completed the presentinvention.

That is, the present invention provides an electroacoustic conversionfilm web, an electroacoustic conversion film, a manufacturing method ofan electroacoustic conversion film web, and a manufacturing method of anelectroacoustic conversion film with the following configurations.

(1) A manufacturing method of an electroacoustic conversion film webincluding a piezoelectric layer having dielectric properties, two thinfilm electrodes respectively formed on both surfaces of thepiezoelectric layer, and two protective layers respectively formed onthe two thin film electrodes, the method comprising: a preparation stepof preparing an electrode laminated body in which one of the thin filmelectrodes and one of the protective layers are laminated; and alamination step of laminating the electrode laminated body and thepiezoelectric layer, in which wherein, in the lamination step, in a casewhere the electrode laminated body and the piezoelectric layer arelaminated, at least one end portion of the thin film electrode isprovided with a non-adhered portion that is not adhered to thepiezoelectric layer.

(2) The manufacturing method of an electroacoustic conversion film webaccording to (1), in which the lamination step is a first laminationstep of forming the piezoelectric layer by applying a coatingcomposition that is to become the piezoelectric layer onto the thin filmelectrode of the electrode laminated body and thereafter curing thecoating composition, and laminating the electrode laminated body and thepiezoelectric layer, and in the first lamination step, in a case wherethe coating composition is applied, the non-adhered portion is formed bycausing the at least one end portion of the thin film electrode to be acoating material non-coated portion to which the coating composition isnot applied.

(3) The manufacturing method of an electroacoustic conversion film webaccording to (1), in which the lamination step is a second laminationstep of laminating the electrode laminated body and the piezoelectriclayer by bonding the piezoelectric layer to the thin film electrode sideof the electrode laminated body, and in the second lamination step, thenon-adhered portion is formed by causing the at least one end portion ofthe thin film electrode to be a non-bonded portion to which thepiezoelectric layer is not bonded.

(4) The manufacturing method of an electroacoustic conversion film webaccording to (1), in which the preparation step is a step of preparingtwo electrode laminated bodies having different sizes, the laminationstep includes a first lamination step of forming the piezoelectric layerby applying a coating composition that is to become the piezoelectriclayer onto the thin film electrode of the electrode laminated bodyhaving a larger size and thereafter curing the coating composition, andlaminating the electrode laminated body having a larger size and thepiezoelectric layer, and a second lamination step of laminating theelectrode laminated body having a smaller size and the piezoelectriclayer by bonding the thin film electrode side of the electrode laminatedbody having a smaller size to the surface of the piezoelectric layer onthe opposite side to the surface on which the electrode laminated bodyhaving a larger size is laminated, the electrode laminated body having alarger size being laminated on the piezoelectric layer, in the firstlamination step, in a case where the coating composition is applied, thenon-adhered portion is formed by causing the at least one end portion ofthe thin film electrode to be a coating material non-coated portion towhich the coating composition is not applied, and in the secondlamination step, the non-adhered portion is formed by causing the atleast one end portion of the thin film electrode to be a non-bondedportion to which the piezoelectric layer is not bonded.

(5) The manufacturing method of an electroacoustic conversion film webaccording to (3) or (4), in which the second lamination step includes anadhesive application step of applying an adhesive to the thin filmelectrode side of the electrode laminated body, and a bonding step ofbonding the piezoelectric layer to the electrode laminated body via theadhesive, and in the adhesive application step, the non-adhered portionis forming by causing the at least one end portion of the thin filmelectrode to be an adhesive non-coated portion to which the adhesive isnot applied.

(6) The manufacturing method of an electroacoustic conversion film webaccording to any one of (3) to (5), in which the second lamination stepis to bond the piezoelectric layer to the electrode laminated bodythrough compression bonding, and the non-adhered portion is formed bycausing the at least one end portion of the thin film electrode to be anon-compression-bonded portion to which the piezoelectric layer is notcompression-bonded.

(7) The manufacturing method of an electroacoustic conversion film webaccording to any one of (3) to (6), in which, in the second laminationstep, the non-adhered portion is formed by masking the at least one endportion of the thin film electrode and bonding the piezoelectric layerto the electrode laminated body.

(8) The manufacturing method of an electroacoustic conversion film webaccording to any one of (3) to (7), in which, in the second laminationstep, an area of the thin film electrode laminated on the piezoelectriclayer in a view in a direction perpendicular to a principal surface ofthe piezoelectric layer is smaller than an area of the piezoelectriclayer.

(9) The manufacturing method of an electroacoustic conversion film webaccording to any one of (1) to (8), in which a width of the non-adheredportion is 5 to 20 mm.

(10) The manufacturing method of an electroacoustic conversion film webaccording to any one of (1) to (9), in which a shape of a principalsurface of the thin film electrode is a quadrangular shape, and endportions of two edges of the thin film electrode which oppose each otherserve as the non-adhered portions.

(11) The manufacturing method of an electroacoustic conversion film webaccording to any one of (1) to (10), in which a thickness of theelectrode laminated body is 4 to 20 μm.

(12) The manufacturing method of an electroacoustic conversion film webaccording to any one of (1) to (11), in which the piezoelectric layer isa polymer composite piezoelectric body in which piezoelectric bodyparticles are dispersed in a viscoelastic matrix formed of a polymermaterial having viscoelasticity at a normal temperature.

(13) The manufacturing method of an electroacoustic conversion film webaccording to (12), in which a local maximum value at which a losstangent Tan δ at a frequency of 1 Hz becomes greater than or equal to0.5 due to measurement of a dynamic viscoelasticity of the polymermaterial is present in a temperature range of 0° C. to 50° C.

(14) The manufacturing method of an electroacoustic conversion film webaccording to (12) or (13), in which the polymer material has acyanoethyl group.

(15) The manufacturing method of an electroacoustic conversion film webaccording to any one of (12) to (14), in which the polymer material iscyanoethylated polyvinyl alcohol.

(16) A manufacturing method of an electroacoustic conversion film,comprising: a cutting step of cutting the electroacoustic conversionfilm web prepared in the manufacturing method of an electroacousticconversion film web according to any one of (1) to (15), into apredetermined shape, in which, in the cutting step, the electroacousticconversion film web is cut into a shape in which at least a portion ofthe non-adhered portion of the thin film electrode remains.

(17) An electroacoustic conversion film web comprising: a piezoelectriclayer having dielectric properties; an upper thin film electrode formedon one principal surface of the piezoelectric layer; a lower thin filmelectrode formed on the other principal surface of the piezoelectriclayer; an upper protective layer formed on the upper thin filmelectrode; and a lower protective layer formed on the lower thin filmelectrode, in which, in a view in a direction perpendicular to theprincipal surface of the piezoelectric layer, an area of the lower thinfilm electrode is larger than an area of the piezoelectric layer, and atleast one end portion of the lower thin film electrode has a non-adheredportion on which the piezoelectric layer is not laminated, and in theview in the direction perpendicular to the principal surface of thepiezoelectric layer, an area of the upper thin film electrode is smallerthan the area of the piezoelectric layer, and at least one end portionof the upper thin film electrode has a non-adhered portion to which thepiezoelectric layer is not adhered.

(18) An electroacoustic conversion film web comprising: a piezoelectriclayer having dielectric properties; two thin film electrodesrespectively formed on both surfaces of the piezoelectric layer; and twoprotective layers respectively formed on the two thin film electrodes,in which, in a view in a direction perpendicular to a principal surfaceof the piezoelectric layer, an area of each of the two thin filmelectrodes is smaller than an area of the piezoelectric layer, and atleast one end portion of each of the thin film electrodes has anon-adhered portion to which the piezoelectric layer is not adhered.

(19) An electroacoustic conversion film comprising: a piezoelectriclayer having dielectric properties; two thin film electrodesrespectively formed on both surfaces of the piezoelectric layer; twoprotective layers respectively formed on the two thin film electrodes;regions in which the piezoelectric layer, the two thin film electrodes,and the two protective layers have the same shape and are adhered; andregions in which the piezoelectric layer, the two thin film electrodes,and the two protective layers overlap in a lamination direction and thepiezoelectric layer and the two thin film electrodes are not adhered.

With the electroacoustic conversion film web, the electroacousticconversion film, the manufacturing method of an electroacousticconversion film web, and the manufacturing method of an electroacousticconversion film of the present invention, costs can be reduced byreducing, the number of operations without damage to thin filmelectrodes, the points of electrode lead-out portions can be freelydetermined, and thus high productivity can be achieved.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic perspective view schematically illustrating anexample of the electroacoustic conversion film web of the presentinvention.

FIG. 1B is sectional view taken along line B-B of FIG. 1A.

FIG. 2 is a partial enlarged sectional view of the electroacousticconversion film web.

FIG. 3 is a schematic sectional view of an example of theelectroacoustic conversion film web of the present invention.

FIG. 4A is a conceptual view illustrating an example of a manufacturingmethod of an electroacoustic conversion film web of the presentinvention.

FIG. 4B is a conceptual view illustrating the example of themanufacturing method of an electroacoustic conversion film web of thepresent invention.

FIG. 4C is a conceptual view illustrating the example of themanufacturing method of an electroacoustic conversion film web of thepresent invention.

FIG. 4D is a conceptual view illustrating the example of themanufacturing method of an electroacoustic conversion film web of thepresent invention.

FIG. 4E is a conceptual view illustrating the example of themanufacturing method of an electroacoustic conversion film web of thepresent invention.

FIG. 5A is a schematic perspective view illustrating an example of themanufacturing method of an electroacoustic conversion film web of thepresent invention.

FIG. 5B is a schematic perspective view illustrating the example of themanufacturing method of an electroacoustic conversion film web of thepresent invention.

FIG. 5C is a schematic perspective view illustrating the example of themanufacturing method of an electroacoustic conversion film web of thepresent invention.

FIG. 6 is a schematic perspective view illustrating another example ofthe manufacturing method of an electroacoustic conversion film web ofthe present invention.

FIG. 7A is a schematic perspective view illustrating another example ofthe manufacturing method of an electroacoustic conversion film web ofthe present invention.

FIG. 7B is a schematic perspective view illustrating another example ofthe manufacturing method of an electroacoustic conversion film web ofthe present invention.

FIG. 8 is a schematic perspective view illustrating a cutting step in amanufacturing method of an electroacoustic conversion film of thepresent invention.

FIG. 9A is a conceptual view illustrating an example of a piezoelectricspeaker that uses an electroacoustic conversion film of the presentinvention.

FIG. 9B is a conceptual view illustrating the example of thepiezoelectric speaker that uses the electroacoustic conversion film ofthe present invention.

FIG. 9C is a conceptual view illustrating the example of thepiezoelectric speaker that uses the electroacoustic conversion film ofthe present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, an electroacoustic conversion film web, an electroacousticconversion film, a manufacturing method of an electroacoustic conversionfilm web, and a manufacturing method of an electroacoustic conversionfilm of the present invention will be described in detail based onpreferred embodiments shown in the accompanying drawings.

Descriptions of the constituent elements described below may be madebased on representative embodiments of the present invention, but thepresent invention is not limited to the embodiments.

In this specification, a numerical range represented by using “to” meansa range including numerical values described before and after “to” as alower limit and an upper limit.

In this application, the “electroacoustic conversion film web” refers toa state before being processed (cut) into the electroacoustic conversionfilm with a final shape assembled into an electroacoustic transducersuch as a speaker, and may be a film-like (sheet-like) material or maybe a long film-like material. In the case of a long film-like material,the electroacoustic conversion film web may be wound into a roll shape,and in a case where the electroacoustic conversion film is processed,the electroacoustic conversion film web may be unwound from the rollaround with the electroacoustic conversion film web is wound.

[Electroacoustic Conversion Film Web]

First, the electroacoustic conversion film web of the present inventionprepared in the manufacturing method of an electroacoustic conversionfilm web of the present invention will be described.

A first embodiment of the electroacoustic conversion film web of thepresent invention is an electroacoustic conversion film web including: apiezoelectric layer having dielectric properties; an upper thin filmelectrode formed on one principal surface of the piezoelectric layer; alower thin film electrode formed on the other principal surface of thepiezoelectric layer; an upper protective layer formed on the upper thinfilm electrode; and a lower protective layer formed on the lower thinfilm electrode, in which, in a view in a direction perpendicular to theprincipal surface of the piezoelectric layer, the area of the lower thinfilm electrode is larger than the area of the piezoelectric layer and atleast one end portion of the lower thin film electrode has a non-adheredportion on which the piezoelectric layer is not laminated, and in theview in the direction perpendicular to the principal surface of thepiezoelectric layer, the area of the upper thin film electrode issmaller than the area of the piezoelectric layer and at least one endportion of the upper thin film electrode has a non-adhered portion towhich the piezoelectric layer is not adhered.

The configuration of the electroacoustic conversion film web of thefirst embodiment will be described using FIGS. 1A and 1B.

FIG. 1A is a schematic perspective view illustrating an example of theelectroacoustic conversion film web of the first embodiment of thepresent invention, and FIG. 1B is sectional view taken along line B-B ofFIG. 1A.

An electroacoustic conversion film web (hereinafter, referred to as aconversion film web) 10 illustrated in FIGS. 1A and 1B basicallyincludes a piezoelectric layer 12 which stretches and contracts inresponse to the state of an electric field, a lower thin film electrode14 provided on one surface of the piezoelectric layer 12, a lowerprotective layer 18 provided on the surface of the lower thin filmelectrode 14, an upper thin film electrode 16 provided on the othersurface of the piezoelectric layer 12, and an upper protective layer 20provided on the surface of the upper thin film electrode 16.

Here, as illustrated in FIGS. 1A and 1B, in the conversion film web 10,in a view in a direction perpendicular to the principal surface of thepiezoelectric layer 12, the area of the lower thin film electrode 14 islarger than the area of the piezoelectric layer 12, and each of twoedges of the lower thin film electrode 14 which oppose each other has anon-adhered portion C₁ on which the piezoelectric layer 12 is notlaminated. That is, the width of the lower thin film electrode 14 inleft and right directions in FIG. 1B is larger than the width of thepiezoelectric layer 12.

In addition, in the view in the direction perpendicular to the principalsurface of the piezoelectric layer 12, the area of the upper thin filmelectrode 16 is smaller than the area of the piezoelectric layer 12, thepiezoelectric layer 12 and the upper thin film electrode 16 are adheredto each other via an adhesive layer 17, the area of the upper thin filmelectrode 16 is larger than the area of the adhesive layer 17, and thewidth of the upper thin film electrode 16 in the left and rightdirections in FIG. 1B is larger than the width of the adhesive layer 17.Therefore, each of two edges of the upper thin film electrode 16, whichoppose each other, has a region where the adhesive layer 17 is notformed, that is, a non-adhered portion C₂ to which the piezoelectriclayer 12 is not adhered.

Each of the non-adhered portions C₁ of the lower thin film electrode 14and the non-adhered portions C₂ of the upper thin film electrode 16extends in a direction parallel to the edge where the correspondingnon-adhered portion is formed, and is formed on a region from one edgeadjacent to the edge to the other edge, that is, on the entire region inthe longitudinal direction of the edge.

In addition, any of the two non-adhered portions C₁ and the twonon-adhered portions C₂ are formed at the two edges of the piezoelectriclayer 12 which oppose each other.

As illustrated in FIG. 2, the non-adhered portion C₁ of the lower thinfilm electrode 14 and the non-adhered portion C₂ of the upper thin filmelectrode 16 is a portion to which a wire 36 is connected, that is, anelectrode lead-out portion. By connecting the wire 36 to the electrodelead-out portion, the thin film electrode and the external device can beelectrically conducted.

In the manufacturing method of the electroacoustic conversion film webof the present invention, the non-adhered portion C₁ and the non-adheredportion C₂ which serve as the electrode lead-out portions can be formedwhile damage to the thin film electrodes is prevented and the number ofoperations and costs are reduced.

These points will be described in detail later.

Since the non-adhered portion C₁ and the non-adhered portion C₂ areprovided on the entire region of at least one end portion of the thinfilm electrodes, the positions of the electrode lead-out portions can befreely determined by forming the prepared conversion film web into adesired shape through cutting, and thus the degree of freedom in designis high, resulting in an improvement in productivity.

Here, the width of each of the non-adhered portion C₁ and thenon-adhered portion C₂ in the direction perpendicular to thecorresponding edge is not particularly limited, and from a viewpoint ofensuring the size of an actual driving surface, is preferably 5 to 20mm, and more preferably 8 to 15 mm.

In the illustrated example, the lower thin film electrode 14 isconfigured to have the two non-adhered portions C₁. However, the lowerthin film electrode 14 is not limited thereto, and may have at least onenon-adhered portion C₁. The lower thin film electrode 14 may also beconfigured to be provided with the non-adhered portion C₁ at each of thefour edges of the lower thin film electrode 14 and thus have the fournon-adhered portions C₁.

Similarly, in the illustrated example, the upper thin film electrode 16is configured to have the two non-adhered portions C₂. However, theupper thin film electrode 16 is not limited thereto, and may have atleast one non-adhered portion C₂. The upper thin film electrode 16 mayalso be configured to be provided with the non-adhered portion C₂ ateach of the four edges of the upper thin film electrode 16 and thus havethe four non-adhered portions C₂.

In the illustrated example, the two non-adhered portions C₁ areconfigured to be provided at the two edges which oppose each other.However, the two non-adhered portions C₁ are not limited thereto and mayalso be configured to be provided at two edges which are adjacent toeach other.

Similarly, the two non-adhered portions C₂ may also be configured to beprovided at two edges which are adjacent to each other.

As the number of non-adhered portions increase, the degree of freedom indesign in a case where the electroacoustic conversion film having adesired shape is prepared by cutting the prepared electroacousticconversion film web can be increased. However, in a case where thenon-adhered portions are provided at three or more edges or in a casewhere two non-adhered portions are provided at two adjacent edges, thereis concern that it may be difficult to employ a manufacturing processusing so-called roll-to-roll and thus the manufacturing process maybecome complex.

Therefore, it is preferable that the two non-adhered portions areconfigured to be provided at two edges which oppose each other.

In the illustrated example, the non-adhered portion C₁ of the lower thinfilm electrode 14 and the non-adhered portion C₂ of the upper thin filmelectrode 16 are configured to be formed at the same edge of thepiezoelectric layer 12. However, the non-adhered portion C₁ and thenon-adhered portion C₂ are not limited thereto and may also beconfigured to be formed at different edges of the piezoelectric layer12.

In the illustrated example, the upper thin film electrode 16 is adheredto the piezoelectric layer 12 via the adhesive layer 17. However, theupper thin film electrode 16 and the piezoelectric layer 12 are notlimited thereto, and may be directly adhered to each other throughcompression bonding or the like without the adhesive layer 17.

Next, a second embodiment of the electroacoustic conversion film web ofthe present invention will be described.

The second embodiment of the electroacoustic conversion film web of thepresent invention is an electroacoustic conversion film web including: apiezoelectric layer having dielectric properties; two thin filmelectrodes respectively formed on both surfaces of the piezoelectriclayer; and two protective layers respectively formed on the two thinfilm electrodes, in which, in a view in a direction perpendicular to aprincipal surface of the piezoelectric layer, the area of each of thetwo thin film electrodes is smaller than the area of the piezoelectriclayer, and at least one end portion of each of the thin film electrodeshas a non-adhered portion to which the piezoelectric layer is notadhered.

The configuration of the electroacoustic conversion film web of thesecond embodiment will be described with reference to FIG. 3.

FIG. 3 is a schematic sectional view illustrating an example of theelectroacoustic conversion film web of the second embodiment of thepresent invention,

A conversion film web 10 b illustrated in FIG. 3 is configured toinclude the piezoelectric layer 12, a lower thin film electrode 14 bprovided on one surface of the piezoelectric layer 12, a lowerprotective layer 18 b provided on the surface of the lower thin filmelectrode 14 b, the upper thin film electrode 16 provided on the othersurface of the piezoelectric layer 12, and the upper protective layer 20provided on the surface of the upper thin film electrode 16.

Since the conversion film web 10 b illustrated in FIG. 3 has the sameconfiguration as the conversion film web 10 illustrated in FIG. 1Bexcept that the lower thin film electrode 14 b, the lower protectivelayer 18 b, and the adhesive layer 17 are provided instead of the lowerthin film electrode 14 and the lower protective layer 18, like parts aredenoted by like reference numerals, and different parts are mainlydescribed in the following description.

As illustrated in FIG. 3, in the conversion film web 10 b, in the viewin the direction perpendicular to the principal surface of thepiezoelectric layer 12, the area of the lower thin film electrode 14 bis smaller than the area of the piezoelectric layer 12, thepiezoelectric layer 12 and the lower thin film electrode 14 b areadhered to each other via an adhesive layer 15, the area of the lowerthin film electrode 14 b is larger than the area of the adhesive layer15, and each of two edges of the lower thin film electrode 14 b, whichoppose each other, has the non-adhered portion C₁ which is a regionwhere the adhesive layer 15 is not formed.

That is, the lower thin film electrode 14 b and the lower protectivelayer 18 b have the same configurations as the upper thin film electrode16 and the upper protective layer 20 except that the lower thin filmelectrode 14 b and the lower protective layer 18 b are laminated on theopposite surface of the piezoelectric layer 12.

In the manufacturing method of the electroacoustic conversion film webof the present invention, even in the case of manufacturing theconversion film web of the second embodiment, the non-adhered portion C₁and the non-adhered portion C₂ can be formed while damage to the thinfilm electrodes is prevented and the number of operations and costs arereduced.

In addition, since the non-adhered portion C₁ and the non-adheredportion C₂ are provided on the entire region of at least one end portionof the thin film electrodes even in the conversion film web of thesecond embodiment, in a case where various shapes of conversion filmsare manufactured, the positions of the electrode lead-out portions canbe freely determined by forming the prepared conversion film web into adesired shape through cutting, and thus the degree of freedom in designis high, resulting in an improvement in productivity.

[Electroacoustic Conversion Film]

The electroacoustic conversion film (hereinafter, referred to as“conversion film”) of the present invention has is a conversion filmobtained by cutting the above-described conversion film web into adesired shape and has a shape in which at least a portion of thenon-adhered portion of the thin film electrode remains (see FIG. 8).

Therefore, the conversion film of the present invention is a conversionfilm including: a piezoelectric layer having dielectric properties; twothin film electrodes respectively formed on both surfaces of thepiezoelectric layer; and two protective layers respectively formed onthe two thin film electrodes, in which the piezoelectric layer, the twothin film electrodes, and the two protective layers have regions whichhave the same shape and are adhered, and the piezoelectric layer, thetwo thin film electrodes, and the two protective layers have regionswhich overlap each other in a lamination direction and in which thepiezoelectric layer and the two thin film electrodes are not adhered toeach other.

At least some regions of the non-adhered portions that are remainedduring the cutting are regions are the regions in which thepiezoelectric layer and the two thin film electrodes are not adhered toeach other, and are used as electrode lead-out portions (see FIG. 2).

The conversion film web of the present invention may also be used as theconversion film as it is without being cut.

Next, the material, configuration, and the like of each of constituentelements of the conversion film web and the conversion film will bedescribed.

[Piezoelectric Layer]

In the conversion film web of the present invention, the piezoelectriclayer 12 is a layer which has piezoelectric properties and stretches andcontracts in an in-plane direction in response to the state of anelectric field.

The piezoelectric layer 12 of the conversion film web illustrated inFIGS. 1B and 3 is a polymer composite piezoelectric body in whichpiezoelectric body particles 26 are dispersed in a matrix 24 formed of apolymer material.

In addition, the piezoelectric layer 12 is subjected to polarizationprocessing.

In addition, the piezoelectric body particles 26 in the piezoelectriclayer 12 may be dispersed in the viscoelastic matrix 24 with regularityor may also be irregularly dispersed therein.

Here, it is preferable that a polymer material having viscoelasticity ata normal temperature is used as the material of the matrix 24(matrix-cum-binder) of the polymer composite piezoelectric bodyconfiguring the piezoelectric layer 12.

It is preferable that the polymer composite piezoelectric body (thepiezoelectric layer 12) used in the conversion film web of the presentinvention has the following requisites. Therefore, it is preferable touse a polymer material having viscoelasticity at a normal temperature asthe material having the following requisites.

Furthermore, herein, the “normal temperature” indicates a temperaturerange of approximately 0° C. to 50° C.

(i) Flexibility

For example, in a case of being gripped in a state of being loosely bentlike a newspaper or a magazine as a portable device, the polymercomposite piezoelectric body is continuously subjected to large bendingdeformation from the outside at a comparatively slow vibration of lessthan or equal to a few Hz. At this time, in a case where the polymercomposite piezoelectric body is hard, large bending stress is generatedto that extent, and a crack is generated at the interface between thepolymer matrix and the piezoelectric body particles, and thus thepiezoelectric layer may be broken. Accordingly, the polymer compositepiezoelectric body is required to have suitable flexibility. Inaddition, in a case where strain energy is diffused into the outside asheat, the stress is able to be relieved. Accordingly, the loss tangentof the polymer composite piezoelectric body is required to be suitablylarge.

(ii) Acoustic Quality

In the speaker, the piezoelectric body particles vibrate at a frequencyof an audio band of 20 Hz to 20 kHz, and the entire vibration plate (thepolymer composite piezoelectric body) integrally vibrates due to thevibration energy, and thus a sound is reproduced. Accordingly, in orderto increase the transmission efficiency of the vibration energy, thepolymer composite piezoelectric body is required to have suitablehardness. In addition, in a case where the frequency properties of thespeaker become smooth, the changed amount of the acoustic quality at thetime that the lowest resonance frequency f₀ is changed according to achange in the curvature also decreases. Accordingly, the loss tangent ofthe polymer composite piezoelectric body is required to be suitablylarge.

As described above, the polymer composite piezoelectric body used in theconversion film web of the present invention is required to be rigidwith respect to a vibration of 20 Hz to 20 kHz, and to be flexible withrespect to a vibration of less than or equal to a few Hz. In addition,the loss tangent of the polymer composite piezoelectric body is requiredto be suitably large with respect to the vibration of all frequencies ofless than or equal to 20 kHz.

In general, a polymer solid has a viscoelasticity relieving mechanism,and a molecular movement having a large scale is observed as a decrease(relief) in a storage elastic modulus (Young's modulus) or the localmaximum (absorption) in a loss elastic modulus along with an increase ina temperature or a decrease in a frequency. Among them, the relief dueto a microbrown movement of a molecular chain in an amorphous region isreferred to as main dispersion, and an extremely large relievingphenomenon is observed. A temperature at which this main dispersionoccurs is a glass transition point (Tg), and the viscoelasticityrelieving mechanism is most remarkably observed.

In the polymer composite piezoelectric body (the piezoelectric layer12), the polymer material of which the glass transition point is anormal temperature, in other words, the polymer material havingviscoelasticity at a normal temperature is used in the matrix, and thusthe polymer composite piezoelectric body which is rigid with respect toa vibration of 20 Hz to 20 kHz and is flexible with respect to avibration of less than or equal to a few Hz is realized. In particular,from a viewpoint of preferably exhibiting such behavior, it ispreferable that a polymer material of which the glass transitiontemperature at a frequency of 1 Hz is a normal temperature, that is, 0°C. to 50° C. is used in the matrix of the polymer compositepiezoelectric body.

As the polymer material having viscoelasticity at a normal temperature,various known materials are able to be used. Preferably, a polymermaterial of which the local maximum value of a loss tangent Tan δ at afrequency of 1 Hz at a normal temperature, that is, 0° C. to 50° C. in adynamic viscoelasticity test is greater than or equal to 0.5 is used.

Accordingly, in a case where the polymer composite piezoelectric body isslowly bent due to an external force, stress concentration on theinterface between the polymer matrix and the piezoelectric bodyparticles at the maximum bending moment portion is relieved, and thushigh flexibility is able to be expected.

In addition, it is preferable that, in the polymer material, a storageelastic modulus (E′) at a frequency of 1 Hz according to dynamicviscoelasticity measurement is greater than or equal to 100 MPa at 0° C.and is less than or equal to 10 MPa at 50° C.

Accordingly, it is possible to reduce a bending moment which isgenerated at the time that the polymer composite piezoelectric body isslowly bent due to the external force, and it is possible to make thepolymer composite piezoelectric body rigid with respect to an acousticvibration of 20 Hz to 20 kHz.

In addition, it is more preferable that the relative permittivity of thepolymer material is greater than or equal to 10 at 25° C. Accordingly,in a case where a voltage is applied to the polymer compositepiezoelectric body, a higher electric field is applied to thepiezoelectric body particles in the polymer matrix, and thus a largedeformation amount is able to be expected.

However, in consideration of ensuring excellent moisture resistance orthe like, it is preferable that the relative permittivity of the polymermaterial is less than or equal to 10 at 25° C.

As the polymer material satisfying such conditions, cyanoethylatedpolyvinyl alcohol (cyanoethylated PVA), polyvinyl acetate,polyvinylidene chloride coacrylonitrile, a polystyrene-vinylpolyisoprene block copolymer, polyvinyl methyl ketone, polybutylmethacrylate, and the like are exemplified. In addition, as thesepolymer materials, a commercially available product such as Hybrar 5127(manufactured by Kuraray Co., Ltd.) is also able to be suitably used.Among them, a material having a cyanoethyl group is preferably used, andcyanoethylated PVA is particularly preferably used.

Furthermore, only one of these polymer materials may be used, or aplurality of types thereof may be used in combination (mixture).

The matrix 24 using such a polymer material having viscoelasticity at anormal temperature, as necessary, may use a plurality of polymermaterials in combination.

That is, in order to adjust dielectric properties or mechanicalproperties, other dielectric polymer materials may be added to thematrix 24 in addition to the viscoelastic material such ascyanoethylated PVA, as necessary.

As the dielectric polymer material which is able to be added to thematrix 24, for example, a fluorine-based polymer such as polyvinylidenefluoride, a vinylidene fluoride-tetrafluoroethylene copolymer, avinylidene fluoride-trifluoroethylene copolymer, a polyvinylidenefluoride-trifluoroethylene copolymer, and a polyvinylidenefluoride-tetrafluoroethylene copolymer, a polymer having a cyano groupor a cyanoethyl group such as a vinylidene cyanide-vinyl acetatecopolymer, cyanoethyl cellulose, cyanoethyl hydroxy saccharose,cyanoethyl hydroxy cellulose, cyanoethyl hydroxy pullulan, cyanoethylmethacrylate, cyanoethyl acrylate, cyanoethyl hydroxy ethyl cellulose,cyanoethyl amylose, cyanoethyl hydroxy propyl cellulose, cyanoethyldihydroxy propyl cellulose, cyanoethyl hydroxy propyl amylose,cyanoethyl polyacryl amide, cyanoethyl polyacrylate, cyanoethylpullulan, cyanoethyl polyhydroxy methylene, cyanoethyl glycidolpullulan, cyanoethyl saccharose, and cyanoethyl sorbitol, a syntheticrubber such as nitrile rubber or chloroprene rubber, and the like areexemplified.

Among them, a polymer material having a cyanoethyl group is suitablyused.

Furthermore, the dielectric polymer added to the matrix 24 of thepiezoelectric layer 12 in addition to the material havingviscoelasticity at a normal temperature such as cyanoethylated PVA isnot limited to one dielectric polymer, and a plurality of dielectricpolymers may be added.

In addition, in order to adjust the glass transition point (Tg), athermoplastic resin such as a vinyl chloride resin, polyethylene,polystyrene, a methacrylic resin, polybutene, and isobutylene, and athermosetting resin such as a phenol resin, a urea resin, a melamineresin, an alkyd resin, and mica may be added in addition to thedielectric polymer material.

Furthermore, in order to improve pressure sensitive adhesiveness, aviscosity imparting agent such as rosin ester, rosin, terpene, terpenephenol, and a petroleum resin may be added.

In the matrix 24 of the piezoelectric layer 12, the added amount at thetime of adding a polymer in addition to the viscoelastic material suchas cyanoethylated PVA is not particularly limited, and it is preferablethat a ratio of the added polymer to the matrix 24 is less than or equalto 30 vol %.

Accordingly, it is possible to exhibit the properties of the polymermaterial to be added without impairing the viscoelasticity relievingmechanism of the matrix 24, and thus a preferred result is able to beobtained from a viewpoint of increasing a dielectric constant, ofimproving heat resistance, and of improving adhesiveness between thepiezoelectric body particles 26 and the electrode layer.

Furthermore, in the present invention, the material of the matrix 24 isnot limited to the polymer material having viscoelasticity at a normaltemperature and may also use the above-mentioned dielectric polymer orthe like.

The piezoelectric body particles 26 are formed of ceramics particleshaving a perovskite type or wurtzite type crystal structure.

As the ceramics particles configuring the piezoelectric body particles26, for example, lead zirconate titanate (PZT), lead lanthanum zirconatetitanate (PLZT), barium titanate (BaTiO₃), zinc oxide (ZnO), a solidsolution (BFBT) of barium titanate and bismuth ferrite (BiFe₃), and thelike are exemplified.

The particle diameter of the piezoelectric body particles 26 may beappropriately selected according to the size or usage of the conversionfilm web, and is preferably 1 μm to 10 μm according to the considerationof the present inventors.

By setting the particle diameter of the piezoelectric body particles 26to be in the range described above, a preferred result is able to beobtained from a viewpoint of making high piezoelectric properties andflexibility compatible.

In addition, in FIG. 1, the piezoelectric body particles 26 in thepiezoelectric layer 12 are uniformly dispersed in the matrix 24 withregularity. However, the piezoelectric body particles 26 may also beirregularly dispersed therein.

In the conversion film web of the present invention, a quantitativeratio of the matrix 24 and the piezoelectric body particles 26 in thepiezoelectric layer 12 may be appropriately set according to the size inthe surface direction or the thickness of the conversion film web, theusage of the conversion film web, properties required for the conversionfilm web, and the like.

Here, according to the consideration of the present inventors, thevolume fraction of the piezoelectric body particles 26 in thepiezoelectric layer 12 is preferably 30% to 70%, particularly preferablygreater than or equal to 50%. Therefore, the volume fraction thereof ismore preferably 50% to 70%.

By setting the quantitative ratio of the matrix 24 and the piezoelectricbody particles 26 to be in the range described above, it is possible toobtain a preferred result from a viewpoint of making high piezoelectricproperties and flexibility compatible.

In addition, in the conversion film web of the present invention, thethickness of the piezoelectric layer 12 is not also particularlylimited, and may be appropriately set according to the size of theconversion film web, the usage of the conversion film web, propertiesrequired for the conversion film web, and the like.

Here, according to the consideration of the present inventors, thethickness of the piezoelectric layer 12 is preferably 5 to 100 μm, morepreferably 5 to 50 μm, and particularly preferably 5 to 30 μm.

By setting the thickness of the piezoelectric layer 12 to be in therange described above, it is possible to obtain a preferred result fromviewpoint of making ensuring stiffness and appropriate flexibilitycompatible, responsiveness, and widening of a reproducible band.

Furthermore, as described above, it is preferable that the piezoelectriclayer 12 is subjected to polarization processing (poling). Thepolarization processing will be described below in detail.

In addition, in the embodiment described above, the polymer compositepiezoelectric body is used as the piezoelectric layer 12. However, thepresent invention is not limited thereto, and a polymer piezoelectricmaterial having piezoelectric properties, such as polyvinylidenefluoride (PVDF) may also be used.

While monoaxially stretched PVDF has in-plane anisotropy in thepiezoelectric properties thereof, the polymer composite piezoelectricbody does not have in-plane anisotropy. Therefore, the polymer compositepiezoelectric body is able to more suitably convert a stretching andcontracting movement into a forward and rearward movement compared toPVDF and is thus able to obtain acoustic quality with a sufficient soundvolume, which is preferable.

[Protective Layers]

As illustrated in FIGS. 1B and 3, the conversion film web of the presentinvention has a configuration in which the piezoelectric layer 12 isinterposed between the lower thin film electrode 14 and the upper thinfilm electrode 16, and this laminated body is interposed between thelower protective layer 18 and the upper protective layer 20.

In the conversion film web, the lower protective layer 18 and the upperprotective layer 20 have a function of applying appropriate stiffnessand mechanical strength to the polymer composite piezoelectric body.That is, there may be a case where, in the conversion film web of thepresent invention, the polymer composite piezoelectric body (thepiezoelectric layer 12) consisting of the matrix 24 and thepiezoelectric body particles 26 exhibits extremely superior flexibilityunder bending deformation at a slow vibration but has insufficientstiffness or mechanical strength depending on the usage. Forcompensation for this, the conversion film web is provided with thelower protective layer 18 and the upper protective layer 20.

In addition, since the lower protective layer 18 and the upperprotective layer 20 are different from each other only in position andsize and have the same configuration, in the following description, in acase where there is no need to distinguish between the lower protectivelayer 18 and the upper protective layer 20, both the members arecollectively referred to as a protective layer.

The protective layer is not particularly limited, and may use varioussheet-like materials. As an example, various resin films (plastic films)are suitably exemplified. Among them, by the reason of excellentmechanical properties and heat resistance, polyethylene terephthalate(PET), polypropylene (PP), polystyrene (PS), polycarbonate (PC),polyphenylene sulfite (PPS), polymethyl methacrylate (PMMA),polyetherimide (PEI), polyimide (PI), polyethylene naphthalate (PEN),triacetylcellulose (TAC), and a cyclic olefin-based resin are suitablyused.

The thicknesses of the protective layers are not particularly limited.In addition, the thicknesses of the protective layers may be basicallyidentical to each other or different from each other.

Here, in a case where the stiffness of the protective layer excessivelyincreases, not only is the stretching and contracting of thepiezoelectric layer 12 constrained, but also the flexibility isimpaired, and thus it is advantageous as the thickness of the protectivelayer becomes thinner unless mechanical strength or excellenthandleability as a sheet-like material is required.

Here, according to the consideration of the present inventors, in a casewhere the thickness of each of the protective layers is less than orequal to twice the thickness of the piezoelectric layer 12, it ispossible to obtain a preferred result from a viewpoint of compatibilitybetween ensuring of the stiffness and appropriate flexibility, or thelike.

For example, in a case where the thickness of the piezoelectric layer 12is 50 μm and the lower protective layer 18 and the upper protectivelayer 20 are formed of PET, the thickness of each of the lowerprotective layer 18 and the upper protective layer 20 is preferably lessthan or equal to 100 and more preferably less than or equal to 50 μm,and particularly preferably less than or equal to 25 μM.

[Thin Film Electrodes]

In the conversion film web of the present invention, the lower thin filmelectrode 14 is formed between the piezoelectric layer 12 and the lowerprotective layer 18, and the upper thin film electrode 16 is formedbetween the piezoelectric layer 12 and the upper protective layer 20.

The lower thin film electrode 14 and the upper thin film electrode 16are provided to apply a voltage to the piezoelectric layer 12.

In addition, since the lower thin film electrode 14 and the upper thinfilm electrode 16 are different from each other only in size positionand have the same configuration, in the following description, in a casewhere there is no need to distinguish between the lower thin filmelectrode 14 and the upper thin film electrode 16, both the members arecollectively referred to as a thin film electrode.

In the present invention, a forming material of the thin film electrodeis not particularly limited, and as the forming material, variousconductive bodies are able to be used. Specifically, carbon, palladium,iron, tin, aluminum, nickel, platinum, gold, silver, copper, chromium,molybdenum, or an alloy thereof, indium-tin oxide, and the like areexemplified. Among them, any one of copper, aluminum, gold, silver,platinum, and indium-tin oxide is suitably exemplified.

In addition, a forming method of the thin film electrode is notparticularly limited, and as the forming method, various known methodssuch as a vapor-phase deposition method (a vacuum film forming method)such as vacuum vapor deposition or sputtering, film formation usingplating, and a method of adhering a foil formed of the materialsdescribed above are able to be used.

Among them, in particular, by the reason that the flexibility of theconversion film web is able to be ensured, a copper or aluminum thinfilm formed by using the vacuum vapor deposition is suitably used as thethin film electrode. Among them, in particular, the copper thin filmformed by using the vacuum vapor deposition is suitably used.

The thicknesses of the thin film electrodes are not particularlylimited. In addition, the thicknesses of the thin film electrodes may bebasically identical to each other or different from each other.

Here, like the protective layer described above, in a case where thestiffness of the thin film electrode excessively increases, not only isstretching and contracting of the piezoelectric layer 12 constrained,but also flexibility is impaired. For this reason, in a case where thethin film electrode is in a range where electrical resistance does notexcessively increase, it is advantageous as the thickness becomesthinner.

In addition, according to the consideration of the present inventors, ina case where the product of the thickness of the thin film electrode andthe Young's modulus is less than the product of the thickness of theprotective layer and the Young's modulus, the flexibility is notconsiderably impaired, which is suitable.

For example, in a case of a combination of the protective layer formedof PET (Young's modulus: approximately 6.2 GPa) and the thin filmelectrode formed of copper (Young's modulus: approximately 130 GPa), ina case where the thickness of the protective layer is 25 μm, thethickness of the thin film electrode is preferably less than or equal to1.2 μm, more preferably less than or equal to 0.3 μm, and particularlypreferably less than or equal to 0.1 μm.

As described above, in the conversion film web of the present invention,the piezoelectric layer 12 (the polymer composite piezoelectric body) inwhich the piezoelectric body particles 26 are dispersed in the matrix 24is interposed between the lower thin film electrode 14 and the upperthin film electrode 16, and this laminated body is interposed betweenthe lower protective layer 18 and the upper protective layer 20.

In the conversion film web of the present invention, it is preferablethat the local maximum value in which the loss tangent (Tan δ) at afrequency of 1 Hz according to the dynamic viscoelasticity measurementis greater than or equal to 0.5 exists at a normal temperature.

Accordingly, even in a case where the conversion film web is subjectedto large bending deformation from the outside at a comparatively slowvibration of less than or equal to a few Hz, it is possible toeffectively diffuse the strain energy to the outside as heat, and thusit is possible to prevent a crack from being generated on the interfacebetween the polymer matrix and the piezoelectric body particles.

In the conversion film web of the present invention, it is preferablethat the storage elastic modulus (E′) at a frequency of 1 Hz accordingto the dynamic viscoelasticity measurement is 10 GPa to 30 GPa at 0° C.,and 1 GPa to 10 GPa at 50° C.

Accordingly, the conversion film web is able to have large frequencydispersion in the storage elastic modulus (E′) at a normal temperature.That is, the conversion film 10 is able to be rigid with respect to avibration of 20 Hz to 20 kHz, and is able to be flexible with respect toa vibration of less than or equal to a few Hz.

In addition, in the conversion film web of the present invention, it ispreferable that the product of the thickness and the storage elasticmodulus (E′) at a frequency of 1 Hz according to the dynamicviscoelasticity measurement is 1.0×10⁶ N/m to 2.0×10⁶ (1.0E+06 to2.0E+06) N/m at 0° C., and 1.0×10⁵ N/m to 1.0×10⁶ (1.0E+05 to 1.0E+06)N/m at 50° C.

Accordingly, the conversion film web is able to have appropriatestiffness and mechanical strength within a range not impairing theflexibility and the acoustic properties of the conversion film web.

Furthermore, in the conversion film web of the present invention, it ispreferable that the loss tangent (Tan δ) at a frequency of 1 kHz at 25°C. is greater than or equal to 0.05 in a master curve obtained by thedynamic viscoelasticity measurement.

Accordingly, the frequency properties of a speaker using a conversionfilm cut from the conversion film web become smooth, and thus it is alsopossible to decrease the changed amount of the acoustic quality at thetime that the lowest resonance frequency f₀ is changed according to thechange in the curvature of the speaker.

[Manufacturing Method of Electroacoustic Conversion Film Web]

Next, the manufacturing method of an electroacoustic conversion film webof the present invention will be described.

The manufacturing method of an electroacoustic conversion film web ofthe present invention is a manufacturing method of an electroacousticconversion film web including a piezoelectric layer having dielectricproperties, two thin film electrodes respectively formed on bothsurfaces of the piezoelectric layer, and two protective layersrespectively formed on the two thin film electrodes, the methodincluding: a preparation step of preparing an electrode laminated bodyin which one of the thin film electrodes and one of the protectivelayers are laminated; and a lamination step of laminating the electrodelaminated body and the piezoelectric layer, in which, in the laminationstep, in a case where the electrode laminated body and the piezoelectriclayer are laminated, at least one end portion of the thin film electrodeis provided with a non-adhered portion that is not adhered to thepiezoelectric layer.

Here, the lamination step is at least one of a first lamination stepwhich is a step of forming the piezoelectric layer by applying a coatingcomposition that is to become the piezoelectric layer onto the thin filmelectrode of the electrode laminated body and thereafter curing thecoating composition, and laminating the electrode laminated body and thepiezoelectric layer, in which, in a case where the coating compositionis applied, the non-adhered portion is formed by causing the at leastone end portion of the thin film electrode to be a coating materialnon-coated portion to which the coating composition is not applied, or asecond lamination step which is a step of laminating the electrodelaminated body and the piezoelectric layer by bonding the piezoelectriclayer to the thin film electrode side of the electrode laminated body,in which the non-adhered portion is formed by causing the at least oneend portion of the thin film electrode to be a non-bonded portion towhich the piezoelectric layer is not bonded.

Here, the electrode laminated bodies are laminated on both surfaces ofthe piezoelectric layer. Therefore, the first lamination step may beperformed in a case where the electrode laminated body is laminated onone surface of the piezoelectric layer and the second lamination stepmay be performed in a case where the electrode laminated body islaminated on the other surface of the piezoelectric layer as theelectrode lead-out portion, or the electrode laminated bodies may belaminated on both surfaces in the second lamination step.

Hereinafter, the manufacturing method of an electroacoustic conversionfilm web of the present invention (hereinafter, referred to as amanufacturing method of the present invention) will be described withreference to FIGS. 4A to 4E and FIGS. 5A to 5C.

FIGS. 4A to 4E are conceptual views illustrating an example of themanufacturing method of the present invention, and FIGS. 5A to 5C areschematic perspective views illustrating the second lamination step.

In the following description, the manufacturing method of the presentinvention will be described by describing the manufacturing method forpreparing the electroacoustic conversion film web 10 illustrated inFIGS. 1A and 1B.

[Preparation Step]

The preparation step is a step of preparing the electrode laminated bodyin which the single thin film electrode and the single protective layerare laminated.

First, as illustrated in FIG. 4A, a lower electrode laminated body 11 awhich is a sheet-like material in which the lower thin film electrode 14and the lower protective layer 18 are laminated is prepared.

First, as illustrated in FIG. 4E, an upper electrode laminated body 11 cwhich is a sheet-like material in which the upper thin film electrode 16and the upper protective layer 20 are laminated is prepared.

The lower electrode laminated body 11 a may be prepared by foil ling acopper thin film or the like as the lower thin film electrode 14 on thesurface of the lower protective layer 18 using vacuum vapor deposition,sputtering, plating, and the like.

Similarly, the upper electrode laminated body 11 c may be prepared byforming a copper thin film or the like as the upper thin film electrode16 on the surface of the upper protective layer 20 using vacuum vapordeposition, sputtering, plating, and the like.

Here, the principal surface of the upper electrode laminated body 11 cis smaller than the principal surface of the lower electrode laminatedbody 11 a. In the illustrated example, the principal surface of theupper electrode laminated body 11 c has the same length as one principalsurface of the lower electrode laminated body 11 a and has a differentlength from the other.

In a case where the protective layer is extremely thin, and thus thehandleability is degraded, the protective layer with a separator(temporary supporter) may be used. As the separator, a PET film having athickness of approximately 25 to 100 μm, and the like are able to beused. The separator may be removed after the lamination of the thin filmelectrodes and the protective layers.

Alternatively, a commercially available product in which the copper thinfilm or the like is formed on the protective layer may be used as theelectrode laminated body.

[First Lamination Step]

The first lamination step is the step of forming the piezoelectric layerby applying the coating composition that is to become the piezoelectriclayer onto the thin film electrode of the electrode laminated body andthereafter curing the coating composition, and laminating the electrodelaminated body and the piezoelectric layer. In the present invention, inthe first lamination step, in a case where the coating composition isapplied, the non-adhered portion is formed by causing the at least oneend portion of the thin film electrode to be the coating materialnon-coated portion to which the coating composition is not applied.

First, the coating composition (coating material) is prepared bydissolving a polymer material as the material of a matrix such ascyanoethylated PVA in an organic solvent, adding the piezoelectric bodyparticles 26 such as PZT particles thereto, and stirring and dispersingthe resultant.

The organic solvent is not particularly limited, and as the organicsolvent, various organic solvents are able to be used.

In a case where the lower electrode laminated body 11 a described aboveis prepared and the coating material is prepared, the coating materialis cast (applied) onto the lower thin film electrode 14 side of thelower electrode laminated body 11 a, and the organic solvent isevaporated and dried. Accordingly, as illustrated in FIG. 4B, alaminated body 11 b in which the lower thin film electrode 14 isprovided on the lower protective layer 18 and the piezoelectric layer 12is formed on the lower thin film electrode 14 is prepared.

Here, as described, in the first lamination step, in the case where thecoating composition is applied, the coating composition is applied tonot the entire surface of the lower thin film electrode side of theelectrode laminated body but is applied only to a portion of the regionthereof, and at least one end portion of the thin film electrode (theelectrode laminated body) serves as the coating material non-coatedportion to which the coating composition is not applied.

In this embodiment, as illustrated in FIGS. 4B and 5A, the coatingcomposition is not applied to each of two edges of the lower electrodelaminated body 11 a which oppose each other, and two coating materialnon-coated portions are formed. The coating material non-coated portionsserve as the non-adhered portions C₁ of the conversion film web 10illustrated in FIG. 1B.

A casting method of the coating material is not particularly limited,and as the casting method, all known methods (coating devices) such as aslide coater or a doctor knife are able to be used.

In addition, a method of applying the coating composition only to aportion of the region of the lower thin film electrode 14 side of thelower electrode laminated body 11 a is not particularly limited, and forexample, in a case where the coating material is cast with a slidecoater, the width of the slit opening through which the coating materialis discharged may be adjusted to be smaller than the width of the lowerthin film electrode 14. Alternatively, a region of the end portion thatis to become the coating material non-coated portion may be subjected tomasking, and then the application may be performed.

In addition, as described above, in the conversion film web 10 of thepresent invention, in addition to the viscoelastic material such ascyanoethylated PVA, a polymer piezoelectric material such as PVDF may beadded to the matrix 24.

In a case where the polymer piezoelectric material is added to thematrix 24, the polymer piezoelectric material added to the coatingmaterial may be dissolved.

In a case where the laminated body 11 b in which the lower thin filmelectrode 14 is provided on the lower protective layer 18 and thepiezoelectric layer 12 is formed on the lower thin film electrode 14 isprepared, it is preferable that the piezoelectric layer 12 is subjectedto polarization processing (poling).

A polarization processing method of the piezoelectric layer 12 is notparticularly limited, and as the polarization processing method, a knownmethod is able to be used. As a preferred polarization processingmethod, a method illustrated in FIGS. 4C and 4D is exemplified.

In this method, as illustrated in FIGS. 4C and 4D, for example, a gap gof 1 mm is opened on an upper surface 12 a of the piezoelectric layer 12of the laminated body 11 b, and a rod-like or wire-like corona electrode30 which is able to be moved along the upper surface 12 a is provided.Then, the corona electrode 30 and the lower thin film electrode 14 areconnected to a direct-current power source 32.

Furthermore, heating means for heating and holding the laminated body 11b, for example, a hot plate is prepared.

Then, in a state where the piezoelectric layer 12 is heated and held bythe heating means, for example, at a temperature of 100° C., adirect-current voltage of a few kV, for example, 6 kV, is appliedbetween the lower thin film electrode 14 and the corona electrode 30from the direct-current power source 32, and thus a corona dischargeoccurs. Furthermore, in a state where the gap g is maintained, thecorona electrode 30 is moved (scanned) along the upper surface 12 a ofthe piezoelectric layer 12, and the piezoelectric layer 12 is subjectedto the polarization processing.

During the polarization processing using the corona discharge(hereinafter, for convenience, also referred to as corona polingprocessing), known rod-like moving means may be used to move the coronaelectrode 30.

In addition, in the corona poling processing, a method of moving thecorona electrode 30 is not limited. That is, the corona electrode 30 isfixed, a moving mechanism for moving the laminated body 11 b isprovided, and the polarization processing may be performed by moving thelaminated body 11 b. Moving means for a known sheet-like material may beused to move the laminated body 11 b.

Furthermore, the number of corona electrodes 30 is not limited to one,and the corona poling processing may be performed by using a pluralityof lines of corona electrodes 30.

In addition, the polarization processing is not limited to the coronapoling processing, and normal electric field poling in which adirect-current electric field is directly applied to an object to besubjected to the polarization processing may also be used. However, in acase where this normal electric field poling is performed, it isnecessary that the upper thin film electrode 16 is formed before thepolarization processing.

Before the polarization processing, calender processing may be performedto smoothen the surface of the piezoelectric layer 12 using a heatingroller or the like. By performing the calender processing, lamination ofthe upper electrode laminated body 11 c, which will be described later,is able to be smoothly performed.

[Second Lamination Step]

The second lamination step is the step of laminating the electrodelaminated body and the piezoelectric layer by bonding the piezoelectriclayer to the thin film electrode side of the electrode laminated body.In the present invention, the second lamination step is the step inwhich the non-adhered portion is formed by causing the at least one endportion of the thin film electrode to be the non-bonded portion to whichthe piezoelectric layer is not bonded.

In this embodiment, the second lamination step includes an adhesiveapplication step of applying an adhesive to the thin film electrode sideof the electrode laminated body, and a bonding step of bonding thepiezoelectric layer to the electrode laminated body via the adhesive. Inthe adhesive application step, the non-adhered portion is formed bycausing the at least one end portion of the thin film electrode to be anadhesive non-coated portion to which the adhesive is not applied.

(Adhesive Application Step)

While the polarization processing of the piezoelectric layer 12 of thelaminated body 11 b is performed, the adhesive layer 17 is formed byapplying the adhesive to the upper electrode laminated body 11 c whichis the sheet-like material prepared in the preparation step in which theupper thin film electrode 16 is formed on the upper protective layer 20.

Here, in the adhesive application step, in a case where the adhesive isapplied, the non-adhered portion is applied not the principal surface ofthe upper thin film electrode 16 but is applied only to a portion of theregion thereof such that the at least one end portion of the upper thinfilm electrode 16 becomes the adhesive non-coated portion to which theadhesive is not applied.

In the example illustrated in FIG. 5B, the adhesive is not applied toeach of two edges of the upper electrode laminated body 11 c whichoppose each other, and two adhesive non-coated portions are formed. Theadhesive non-coated portions serve as the non-adhered portions C₂ of theconversion film web 10 illustrated in FIG. 1B.

An application method of the adhesive is not particularly limited, andas the application method, all known methods (coating devices) such as aslide coater or a doctor knife are able to be used.

In addition, a method of applying the adhesive only to a portion of theregion of the upper thin film electrode 16 side of the upper electrodelaminated body 11 c is not particularly limited, and for example, in acase where the adhesive is applied with a slide coater, the width of theslit opening may be adjusted to be smaller than the width of the upperthin film electrode 16. Alternatively, a region of the end portion thatis to become the adhesive non-coated portion may be subjected tomasking, and then the application may be performed.

The material of the adhesive is not particularly limited, and a knownadhesive used for adhesion between the piezoelectric layer and the thinfilm electrode in the conversion film can be appropriately used. In acase where a polymer composite piezoelectric body in which piezoelectricbody particles are dispersed in a matrix formed of a polymer material isused as the piezoelectric layer, the same polymer material as thematerial of the matrix may be used as the adhesive.

(Bonding Step)

Next, as the bonding step, as illustrated in FIGS. 4E and 5C, the upperelectrode laminated body 11 c is bonded to and laminated on thelaminated body 11 b in which the piezoelectric layer 12 is subjected tothe polarization processing while the upper thin film electrode 16 sideon which the adhesive layer 17 is formed faces the piezoelectric layer12 such that the conversion film web 10 is prepared.

Here, the adhesive non-coated portion of the upper electrode laminatedbody 11 c in which the adhesive layer 17 is not formed is not adhered tothe piezoelectric layer 12 and thus becomes the non-adhered portion C₂of the conversion film web 10.

As described above, a piezoelectric film used as a thin speaker needs tobe thinner from viewpoints of not only thinning of the speaker, but alsoresponsiveness and widening of a reproducible band. However, in a thinelectrode layer such as a vapor-deposited film, it is difficult toconnect wires by soldering or the like. In addition, connection of wiresto the thin film electrodes needs to be performed while insulationbetween the thin film electrodes on both surfaces of the piezoelectriclayer is ensured. However, the connection of wires is not easy becausethe thickness of the piezoelectric layer is as thin as approximatelytens of μm.

By adopting a configuration in which an electrode laminated body has anelectrode lead-out portion which protrudes in a convex shape in theouter portion of a piezoelectric layer in a surface direction,electrodes can be drawn from thin film electrodes and connection ofwires by soldering can be easily performed. Furthermore, drawing of theelectrodes can be performed while insulation between the thin filmelectrodes on both surfaces is ensured.

However, in a method of providing the electrode lead-out portionprotruding in a convex shape by entirely laminating the piezoelectriclayer and the electrode laminated body, rubbing the piezoelectric layerwith a cotton swab or the like impregnated with a solvent or the like,and dissolving and removing a portion of the piezoelectric layer, thereis concern that the thin film electrodes may be damaged, for example,the thin film electrodes may be dissolved. In addition, there areproblems that the number of operations increases, the investment infacilities increases, and costs increase.

In addition, since the electrode lead-out portion is forming in a shapeprotruding in a convex shape, it is necessary that the position of theelectrode lead-out portion is determined in advance in a case where anelectroacoustic conversion film is prepared, and the position of theelectrode lead-out portion cannot be changed after the preparation.Therefore, in a case where various shapes of electroacoustic conversionfilms in which the positions, shapes, and the like of electrode lead-outportions vary are prepared, it is necessary that preparation conditionsin a step of forming the electrode lead-out portion are changed for eachof the electroacoustic conversion films, and there is a problem thatproductivity cannot be increased.

In contrast, in the manufacturing method of the present invention, theconfiguration in which, in the lamination step, in a case where theelectrode laminated body and the piezoelectric layer are laminated, thenon-adhered portion that is not adhered to the piezoelectric layer isprovided in at least one end portion of the thin film electrode isprovided.

Specifically, in a case where the coating composition that is to becomethe piezoelectric layer is applied onto the thin film electrode, thenon-adhered portion is formed by causing at least one end portion of thethin film electrode to be the coating material non-coated portion towhich the coating composition is not applied. Alternatively, in a casewhere the electrode laminated body and the piezoelectric layer arelaminated, the non-adhered portion is formed by causing at least one endportion of the thin film electrode to be the non-bonded portion that isnot bonded to the piezoelectric layer.

As described above, in the present invention, in the case where thepiezoelectric layer and the thin film electrode are laminated, thenon-adhered portion that is not adhered to the piezoelectric layer isformed in the thin film electrode. Therefore, there is no need todissolve or remove the piezoelectric layer, and thus the thin filmelectrode is not damaged. In addition, since the non-adhered portionsare formed simultaneously with the step of laminating the piezoelectriclayer and the thin film electrodes, an increase in the number ofoperation steps can be suppressed, and an increase in the investment inthe facilities and costs can be suppressed.

Here, the method of laminating the piezoelectric layer and the electrodelaminated body in the second lamination step is not limited to themethod using the adhesive.

For example, a conversion film web may also be prepared by subjectingthe piezoelectric layer and the electrode laminated body to thermalcompression bonding using a heating press device, a heating roller pair,or the like.

In the case where the piezoelectric layer and the electrode laminatedbody are laminated by the thermal compression bonding, the non-adheredportion may be formed by causing at least one end portion of theelectrode laminated body (the thin film electrode) to be anon-thermal-compression-bonded portion that is notthermal-compression-bonded to the piezoelectric layer.

For example, in a case where thermal compression bonding is performedusing the heating roller, as illustrated in FIG. 6, the non-adheredportion may be formed by subjecting a region other than both endportions of the upper electrode laminated body 11 c to the thermalcompression bonding using a heating roller R having a smaller width thanthe upper electrode laminated body 11 c.

Alternatively, as illustrated in FIGS. 7A and 7B, mask members 80 may bedisposed at both end portions of the upper electrode laminated body 11c, the piezoelectric layer 12 and the upper electrode laminated body 11c may be subjected to compression bonding to adhere the piezoelectriclayer 12 and the upper electrode laminated body 11 c to each other in aregion other than the regions masked with the mask members 80, therebyforming the non-adhered portions in the masked regions of the upperelectrode laminated body 11 c.

In addition, FIG. 7A illustrates an example of a case where thenon-adhered portion of the upper electrode laminated body 11 c (theupper thin film electrode 16) and the non-adhered portion of the lowerthin film electrode 14 are formed on the same edge side of thepiezoelectric layer 12, and FIG. 7B illustrates an example of a casewhere the non-adhered portion of the upper thin film electrode 16 andthe non-adhered portion of the lower thin film electrode 14 are formedon different edge sides of the piezoelectric layer 12.

Here, as described above, the width of the non-adhered portion formed inthe first lamination step and the width of the non-adhered portionformed in the second lamination step is preferably 5 to 20 mm, and morepreferably 8 to 15 mm.

In the above example, the first lamination step and the secondlamination step, the configuration in which the two non-adhered portionsare respectively formed on the two opposing edge sides is adopted.However, the non-adhered portions are not limited thereto, and aconfiguration in which the non-adhered portion is formed at least oneedge side, or a configuration in which non-adhered portions arerespectively formed on four edge sides may be adopted.

In the manufacturing method of the present invention, even in a casewhere the thickness of the electrode laminated body is thin, thenon-adhered portion which serves as the electrode lead-out portion canbe easily formed without damage to the thin film electrode. From thisviewpoint, the manufacturing method of the present invention can be moresuitably applied to a case where the thickness of the electrodelaminated body is 4 to 20 μm.

Here, in the above description, the method of preparing the conversionfilm web illustrated in FIGS. 1A and 1B by performing lamination in thefirst lamination step in the case where the electrode laminated body islaminated on one surface of the piezoelectric layer and performinglamination in the second lamination step in the case where the electrodelaminated body is laminated on the other surface is described. However,the manufacturing method of the present invention is not limitedthereto, and the conversion film web 10 b illustrated in FIG. 3 may alsobe prepared by laminating the electrode laminated bodies on bothsurfaces in the second lamination step.

In a case where the electrode laminated bodies are laminated on bothsurfaces of the piezoelectric layer in the second lamination step,first, the piezoelectric layer is formed on a temporary supporter, andthe electrode laminated body is formed on the opposite surface of thepiezoelectric layer to the temporary supporter by applying the secondlamination step described above. Next, the temporary supporter is peeledoff from the piezoelectric layer, and the electrode laminated body islaminated on the surface of the piezoelectric layer from which thetemporary supporter is peeled off by applying the second laminationstep, thereby preparing the conversion film web 10 b illustrated in FIG.3.

[Manufacturing Method of Electroacoustic Conversion Film]

Next, the manufacturing method of an electroacoustic conversion film ofthe present invention will be described.

The manufacturing method of an electroacoustic conversion film of thepresent invention is a manufacturing method of an electroacousticconversion film, including: a cutting step of cutting the conversionfilm web prepared in the manufacturing method of an electroacousticconversion film web described above, into a predetermined shape, inwhich, in the cutting step, the electroacoustic conversion film web iscut into a shape in which at least a portion of the non-adhered portionof the thin film electrode remains.

(Cutting Step)

The cutting step is a step of cutting the conversion film web 10 inwhich the electrode laminated bodies are laminated on both surfaces ofthe piezoelectric layer in the lamination step into a predeterminedshape.

Here, the conversion film web 10 is cut into a shape in which at leastportions of the non-adhered portion C₁ of the lower thin film electrode14 and the non-adhered portion C₂ of the upper thin film electrode 16remain.

For example, the example illustrated in FIG. 8 illustrates an example inwhich the conversion film web 10 is cut to cut out a star shapeindicated by the two-dot chain line. In FIG. 8, the conversion film webis cut to include the non-adhered portions C₁ and C₂ in the partindicated by a in the figure and is used as a conversion film.

The conversion film prepared as described above has a shape havingregions in which the piezoelectric layer, the two thin film electrodes,and the two protective layers have the same shape and are adhered, andregions in which the piezoelectric layer, the two thin film electrodes,and the two protective layers overlap in a lamination direction and thepiezoelectric layer and the two thin film electrodes are not adhered.The regions in which the piezoelectric layer and the two thin filmelectrodes are are not adhered can be used as the electrode lead-outportions.

In the present invention, the predetermined shape is a desired shapeaccording to the shape of a thin speaker to be used, or the like. Theshape (predetermined shape) of the conversion film cut in the cuttingstep is not particularly limited, and may be appropriately set accordingto the shape of the thin speaker to be used, or the like.

In the conversion film web prepared in the manufacturing method of thepresent invention, since the non-adhered portion is provided on theentire region of at least one end portion of the thin film electrode,the position of the electrode lead-out portion can be freely determinedby cutting the conversion film web to allow a portion of the non-adheredportion of the conversion film web to remain in a case where aconversion film is prepared, and thus the conversion film web can beformed in a desired shape. Therefore, the degree of freedom in design ishigh. Accordingly, various shapes of conversion films can be easilyprepared, and productivity can be improved.

[Electroacoustic Transducer]

Next, an electroacoustic transducer using the conversion film preparedin the manufacturing method of the present invention will be described.

FIG. 9A is a schematic sectional view illustrating an example of theelectroacoustic transducer using the conversion film of the presentinvention, and FIG. 9B is a plan view of FIG. 9A. That is, FIG. 9A is asectional view taken along line a-a in FIG. 9B.

An electroacoustic transducer 40 illustrated in FIGS. 9A and 9B is aflat type piezoelectric speaker in which a conversion film 44 of thepresent invention described above is used as a speaker diaphragm forconverting an electrical signal into vibration energy.

The piezoelectric speaker 40 is able to be used as a microphone, asensor for an instrument, or the like.

The piezoelectric speaker 40 in the illustrated example basicallyincludes the conversion film 44 (piezoelectric film), a case 42, aviscoelastic supporter 46, and a frame 48.

The conversion film 44 is a conversion film formed by cutting theconversion film web of the present invention into a substantiallyrectangular shape.

The case 42 is a thin housing formed of plastic or the like in a squaretubular shape in which one side is open. In the piezoelectric speakerusing the conversion film of the present invention, the case 42 (thatis, the piezoelectric speaker) is not limited to the square tubularshape, and a housing having various shapes such as a cylindrical shapeand a rectangular tubular shape having a rectangular bottom surface isable to be used.

In addition, the frame 48 is a plate material which has an opening atthe center and has a shape similar to the upper end surface (open side)of the case 42.

Furthermore, the viscoelastic supporter 46 has moderate viscosity andelasticity, supports the conversion film 44, and applies a constantmechanical bias to any place of the conversion film so as to convert thestretching and contracting movement of the conversion film into aforward and rearward movement (a movement in a direction perpendicularto the surface of a film). As an example, wool felt, nonwoven fabric ofwool felt including rayon or PET, a foamed material (foamed plastic)such as glass wool or polyurethane, a laminate of a plurality of sheetsof paper, a coating material, and the like are exemplified.

In the illustrated example, the viscoelastic supporter 46 has aquadrangular prism shape having a slightly larger bottom surface shapethan the bottom surface of the case 42.

The specific gravity of the viscoelastic supporter 46 is notparticularly limited and may be appropriately selected according to thetype of the viscoelastic supporter. As an example, in a case where feltis used as the viscoelastic supporter, the specific gravity thereof ispreferably 50 to 500 kg/m³, and more preferably 100 to 300 kg/m³. In acase where glass wool is used as the viscoelastic supporter, thespecific gravity thereof is preferably 10 to 100 kg/m³.

The piezoelectric speaker 40 is configured by accommodating theviscoelastic supporter 46 in the case 42, covering the case 42 and theviscoelastic supporter 46 with the conversion film 44, and in a state inwhich the periphery of the conversion film 44 is pressed against theupper end surface of the case 42 by the frame 48, fixing the frame 48 tothe case 42.

A method of fixing the frame to the case 42 is not particularly limited,and various known methods such as a method using a screw and a bolt nutand a method using a fixing jig are able to be used.

Here, in the piezoelectric speaker 40, the viscoelastic supporter 46 hasa quadrangular prism shape in which the height (thickness) is greaterthan the height of the inner surface of the case 42. That is, asschematically illustrated in FIG. 9C, in a state before the conversionfilm 44 and the frame 48 are fixed, the viscoelastic supporter 46 is ina state protruding from the upper surface of the case 42.

Therefore, in the piezoelectric speaker 40, the viscoelastic supporter46 is held in a state in which the viscoelastic supporter 46 is presseddownward by the conversion film 44 and decreases in thickness toward theperipheral portion of the viscoelastic supporter 46. That is, theprincipal surface of the conversion film 44 is held in a curved state.

At this time, it is preferable that the entire surface of theviscoelastic supporter 46 is pressed in the surface direction of theconversion film 44 so that the thickness decreases over the entiresurface. That is, it is preferable that the entire surface of theconversion film 44 is pressed and supported by the viscoelasticsupporter 46.

In the piezoelectric speaker 40 using the conversion film 44 of thepresent invention, the pressing force of the conversion film 44 exertedon the viscoelastic supporter 46 is not particularly limited, and ispreferably about 0.02 to 0.2 MPa in terms of surface pressure at aposition where the surface pressure is low.

In the illustrated example, regarding the height difference of theconversion film 44 assembled into the piezoelectric speaker 40, thedistance between the point nearest to the bottom surface of the frame 48and the point furthest from the bottom surface is not particularlylimited, and is preferably 1 to 50 mm, and particularly preferably about5 to 20 mm from viewpoints of obtaining a thin flat speaker and enablingthe conversion film 44 to sufficiently perform an upward and downwardmovement.

In addition, although the thickness of the viscoelastic supporter 46 isnot particularly limited, the thickness thereof before pressing isparticularly 1 to 100 mm, and particularly preferably 10 to 50 mm.

In the piezoelectric speaker 40, in a case where the conversion film 44is stretched in the in-plane direction due to the application of avoltage to the piezoelectric layer 12, the conversion film 44 movesupward (in the radial direction of sound) in order to absorb thestretching.

Conversely, in a case where the conversion film 44 is contracted in thein-plane direction due to the application of a voltage to thepiezoelectric layer 12, the conversion film 44 moves downward (towardthe case 42) in order to absorb the contraction.

The piezoelectric speaker 40 generates a sound by vibrations caused byrepetition of stretching and contraction of the conversion film 44.

In the piezoelectric speaker 40, the viscoelastic supporter 46 is in astate of being more compressed in the thickness direction as itapproaches the frame 48. However, due to the static viscoelastic effect(stress relaxation), a constant mechanical bias can be maintained at anyplace of the conversion film 44. Accordingly, the stretching andcontracting movement of the conversion film 44 is efficiently convertedinto a forward and rearward movement, so that it is possible to obtain aflat piezoelectric speaker 40 that is thin, achieves a sufficient soundvolume, and has excellent acoustic properties.

Here, in the piezoelectric speaker 40 in the illustrated example, theentire peripheral area of the conversion film 44 is pressed against thecase 42 (that is, the viscoelastic supporter 46) by the frame 48, butthe present invention is not limited thereto.

That is, the electroacoustic transducer using the conversion film 44 ofthe present invention is also able to use a configuration in which theconversion film 44 is pressed against and fixed to the surface of thecase 42 by screws, bolt nuts, holding devices, or the like, for example,at the four corners of the case 42 without using the frame 48.

An O-ring or the like may be interposed between the case 42 and theconversion film 44. With this configuration, a damper effect is able tobe achieved, and it is possible to prevent the vibration of theconversion film 44 from being transmitted to the case 42, and to obtainmore excellent acoustic properties.

In addition, the electroacoustic transducer using the conversion film 44may be configured to include a support plate on which the viscoelasticsupporter 46 is placed instead of the case 42 that accommodates theviscoelastic supporter 46.

That is, a configuration in which the viscoelastic supporter 46 isplaced on the support plate having stiffness, the conversion film 44 isplaced to cover the viscoelastic supporter 46, the same frame 48 asdescribed above is placed on the peripheral portion of the conversionfilm 44, and the frame 48 is fixed to the support plate by screws or thelike to press the viscoelastic supporter 46 against the conversion film44 together with the frame 48 and bend the conversion film 44 is alsoable to be used.

Furthermore, even in this configuration that does not have the case 42,the conversion film 44 may be held in a state where the viscoelasticsupporter 46 is pressed and thinned by screws or the like without usingthe frame 48.

A configuration in which the vibration of the conversion film 44 isfurther amplified by using various vibration plates made of polystyrene,foamed PET, or carbon fiber as the material of the support plate may beadopted.

Moreover, the electroacoustic transducer using the conversion film 44 isnot limited to the configuration that presses the periphery, and forexample, a configuration in which points other than the periphery of thelaminated body of the viscoelastic supporter 46 and the conversion film44 are pressed by some means and at least a portion of the conversionfilm 44 is held in a curved state is also able to be used.

Alternatively, a configuration in which a resin film is attached to theconversion film 44 to apply (hold) a tension thereto may also beadopted. By configuring the conversion film to be held with the resinfilm and causing the conversion film to be held in a curved state, aflexible speaker is able to be obtained.

Alternatively, the conversion film 44 may be configured to be stretchedover a curved frame.

In addition, the electroacoustic transducer using the conversion film ofthe present invention is not limited to the configuration using theviscoelastic supporter 46.

For example, a configuration including an elastic supporter havingelasticity instead of the viscoelastic supporter 46 may be provided. Asthe elastic supporter, natural rubber and various synthetic rubbers areexemplified.

Alternatively, a configuration in which an airtight material having thesame shape as that of the case 42 is used as a case, the open end of thecase is covered and closed by the conversion film 44, gas is introducedinto the case to apply a pressure to the conversion film 44, and theconversion film 44 is thus held in a convexly swollen state may beprovided.

In the configuration in which a pressure is applied to the inside, thedistortion component increases due to the influence of the air spring,and there is concern that the acoustic quality may deteriorate. On theother hand, in the case of the configuration in which the conversionfilm 44 is supported by a viscoelastic supporter such as glass wool orfelt, since viscosity is imparted, the distortion component does notincrease, which is preferable.

In addition, those other than the gas may fill the case, and a magneticfluid or a coating material is able to be used as long as an appropriateviscosity is able to be imparted.

Furthermore, the combination using the viscoelastic supporter and theconfiguration in which a pressure is applied to the inside may becombined.

The conversion film 44 itself may be molded in advance into a convexshape or a concave shape. In that time, the entirety of the conversionfilm 44 may be molded into a convex shape or a concave shape, or aportion of the conversion film 44 may be molded into a convex portion(concave portion). A forming method of the convex portion is notparticularly limited, and various known processing methods of resinfilms are able to be used. For example, the convex portion is able to beformed by a vacuum pressure molding method or a forming method such asembossing.

The electroacoustic conversion film of the present invention is able tobe suitably used as a speaker by being assembled with a flexible displaysuch as an organic EL display. Furthermore, since the electroacousticconversion film of the present invention is thin, the electroacousticconversion film is able to be suitably assembled with a thin displaydevice such as a liquid crystal display device, an electronic paper, anda screen for a projector.

With such a configuration, it is possible to improve the designproperties and entertainment properties of the conversion film. Further,by integrating the conversion film as a speaker with a screen or adisplay, it is possible to reproduce a sound in a direction in which animage is displayed, and to improve a sense of realism.

In addition, the screen for a projector is flexible and is thus able tobe provided with curvature. By causing an image display surface to beprovided with curvature, it is possible to make the distance from anobserver to the screen substantially uniform between the center and theend portion of the screen, and it is possible to improve a sense ofrealism.

In the case where the image display surface is provided with curvatureas described above, distortion occurs in the projected image. Therefore,it is preferable to perform image processing on the data of theprojected image so as to reduce the distortion according to thecurvature of the image display surface.

Furthermore, as described above, in the conversion film 44 of thepresent invention, the piezoelectric layer 12 also has a capability ofconverting vibration energy into an electrical signal.

Therefore, by using this, the conversion film 44 of the presentinvention is able to be suitably used also in a microphone or a sensor(pickup) for a musical instrument. For example, since the conversionfilm 44 of the present invention has flexibility, the conversion film 44is able to be attached to a throat portion of a person having a complexcurved surface, and acts as a vocal cord microphone merely by beingattached to the vicinity of the vocal cord.

As described above, the electroacoustic conversion film of the presentinvention and the manufacturing method thereof are described in detail,but the present invention is not limited to the examples describedabove, and various improvements or modifications may be performed withina range not deviating from the gist of the present invention.

EXAMPLES

Hereinafter, the present invention will be described in more detail withreference to specific examples of the present invention.

Example 1

According to the method illustrated in FIGS. 4A to 4E and FIGS. 5A to 5Cdescribed above, the conversion film web 10 of the present inventionillustrated in FIGS. 1A and 1B was prepared.

[Preparation Step]

First, a lower electrode laminated body 11 a in which a copper thin filmhaving a thickness of 0.1 μm was vacuum vapor deposited on a PET filmhaving a thickness of 4 μm and a size of 200 mm×350 mm, and an upperelectrode laminated body 11 c in which a copper thin film having athickness of 0.1 μm was vacuum vapor deposited on a PET film having athickness of 4 μm and a size of 180 mm×350 mm were prepared. That is, inthis example, the lower thin film electrode 14 and the upper thin filmelectrode 16 are copper vapor deposition thin films having a thicknessof 0.1 μm, and the lower protective layer 18 and the upper protectivelayer 20 are PET films having a thickness of 4 μm.

In order to obtain good handleability during the process, as the PETfilm, a film with a separator (temporary supporter PET) having athickness of 50 μm attached thereto was used, and the separator of eachprotective layer was removed after the preparation of the conversionfilm web.

[First Lamination Step A]

Next, cyanoethylated PVA (CR-V manufactured by Shin-Etsu Chemical Co.,Ltd.) was dissolved in dimethylformamide (DMF) at the followingcompositional ratio. Thereafter, PZT particles were added to thissolution at the following compositional ratio, and were dispersed byusing a propeller mixer (rotation speed 2000 rpm), and thus a coatingmaterial A for forming the piezoelectric layer 12 was prepared.

-   -   PZT Particles 300 parts by mass    -   Cyanoethylated PVA 30 parts by mass    -   DMF 70 parts by mass

In addition, the PZT particles were obtained by sintering commerciallyavailable PZT raw material powder at 1000° C. to 1200° C. and thereaftercrushing and classifying the resultant so as to have an average particlediameter of 5 μm.

The piezoelectric layer 12 formed by using the coating material A is apolymer composite piezoelectric body in which the PZT particles as thepiezoelectric body particles 26 are dispersed in cyanoethylated PVA asthe matrix 24 formed of a polymer material.

The prepared coating material A for forming the piezoelectric layer 12was applied onto the lower thin film electrode 14 (the copper vapordeposition thin film) of the lower electrode laminated body 11 aprepared in advance by using a slide coater. Furthermore, the coatingmaterial A was applied such that the film thickness of the coating filmafter being dried was 40 μm.

Here, the application was performed by setting the width of the slitopening of the slide coater during the application to 180 mm such thatthe regions of the two opposing edges as the long sides of the lowerthin film electrode 14 became coating material non-coated portions.

That is, the width of the coating material non-coated portion serving asthe non-adhered portion C₁ was set to 10 mm.

Next, a material in which the coating material A was applied onto thelower electrode laminated body 11 a was heated and dried on a hot plateat 120° C. such that DMF was evaporated. Accordingly, the laminated body11 b was prepared in which the lower thin film electrode 14 made ofcopper was formed on the lower protective layer 18 made of PET, and thepiezoelectric layer 12 having a thickness of 40 μm was formed thereon.

The piezoelectric layer 12 of the laminated body 11 b was subjected tothe polarization processing by corona poling illustrated in FIGS. 4C and4D. Furthermore, the polarization processing was performed by settingthe temperature of the piezoelectric layer 12 to 100° C., applying adirect-current voltage of 6 kV between the lower thin film electrode 14and the corona electrode 30 so as to cause corona discharge to occur.

[Second Lamination Step A]

(Adhesive Application Step)

First, an adhesive (CYANORESIN CR-V manufactured by Shin-Etsu ChemicalCo., Ltd.) was applied to the upper thin film electrode 16 side of theupper electrode laminated body 11 c.

Here, the application was performed by setting the width of one ofapplication regions during the application of the adhesive to 160 mmsuch that the regions of the two opposing edges as the long sides of theupper thin film electrode 16 became adhesive non-coated portions.

That is, the width of the adhesive non-coated portion serving as thenon-adhered portion C₂ was set to 10 mm.

(Bonding Step)

Next, the upper electrode laminated body 11 c to which the adhesive wasapplied was placed on and bonded to the laminated body 11 b subjected tothe polarization processing while the adhesive side faced thepiezoelectric layer 12 such that the conversion film web 10 wasprepared.

Thereafter, the wire 36 as the electrode lead-out portion is connectedto each of the non-adhered portions C₁ of the lower thin film electrode14 and the non-adhered portions C₂ of the upper thin film electrode 16.

Example 2

A conversion film web was prepared in the same manner as in Example 1except that the second lamination step A was changed to a secondlamination step B described below.

[Second Lamination Step B]

The upper electrode laminated body 11 c was laminated on the laminatedbody 11 b which was subjected to the polarization processing while theupper thin film electrode 16 faced the piezoelectric layer 12.

Next, the laminated body of the laminated body 11 b and the upperelectrode laminated body 11 c was subjected to thermal compressionbonding at 120° C. by using a laminator device, and thus thepiezoelectric layer 12 and the upper thin film electrode 16 were adheredto each other.

Here, as illustrated in FIG. 6, by using a heating roller having anarrower width than the upper electrode laminated body during thethermal compression bonding, the non-adhered portions C₂ asnon-thermal-compression-bonded portions that were notthermal-compression-bonded were formed in the regions of the twoopposing edges of the upper electrode laminated body 11 c.

Example 3

A conversion film web was prepared in the same manner as in Example 1except that the second lamination step A was changed to a secondlamination step C described below.

[Second Lamination Step C]

The upper electrode laminated body 11 c was laminated on the laminatedbody 11 b which was subjected to the polarization processing while theupper thin film electrode 16 faced the piezoelectric layer 12.

Next, as illustrated in FIG. 7A, the mask members 80 were disposed inthe regions of the two opposing edges of the upper electrode laminatedbody 11 c between the piezoelectric layer 12 and the upper thin filmelectrode 16.

As the mask member 80, a film-like material formed of polyimide with athickness of 15 μm was used.

Next, the laminated body of the laminated body 11 b and the upperelectrode laminated body 11 c was subjected to thermal compressionbonding at 120° C. by using the laminator device, and thus thepiezoelectric layer 12 and the upper thin film electrode 16 were adheredto each other. Thereafter, the mask members 80 were removed.

The masked region of the upper thin film electrode 16 was not adhered tothe piezoelectric layer 12 and became the non-adhered portion C₂.

Examples 4 to 6

Conversion film webs were prepared respectively in the same manners asin Examples 1 to 3 except that PVDF not containing piezoelectric bodyparticles was used as the piezoelectric layer and a coating material Bdescribed below was used as the coating material for forming thepiezoelectric layer.

A coating material containing PVDF and MEK at the followingcompositional ratio was prepared as the coating material B of the PVDFpiezoelectric layer.

-   -   PVDF 100 parts by mass    -   MEK 300 parts by mass

Examples 7 to 9

Conversion film webs were prepared respectively in the same manners asin Examples 1 to 3 except that a highly dielectric polymer describedbelow was used as the piezoelectric layer and a coating material Cdescribed below was used as the coating material for forming thepiezoelectric layer.

A coating material containing the highly dielectric polymer at thefollowing compositional ratio was prepared as the coating material C ofthe piezoelectric layer formed of the highly dielectric polymer.

-   -   Highly dielectric polymer (CYANORESIN CR-S manufactured by        Shin-Etsu Chemical Co., Ltd.) 100 parts by mass    -   Cyclohexanone 300 parts by mass

Comparative Example 1

A conversion film was prepared in the same manner as in Example 1 exceptthat the first lamination step A was changed to a first lamination stepB described below, and the second lamination step A was changed to asecond lamination step D described below.

[First Lamination Step B]

The coating material A was applied to the entire surface of the lowerthin film electrode of the lower electrode laminated body and wasthereafter heated and dried on the hot plate at 120° C. such that DMFwas evaporated, thereby preparing a laminated body in which the lowerthin film electrode was formed on the lower protective layer and thepiezoelectric layer having a thickness of 40 μm was formed thereon.

The laminated body was subjected to the polarization processing, and oneedge of the laminated body was cut to provide a portion protruding in aconvex shape. Furthermore, the piezoelectric layer corresponding to theportion protruding in a convex shape was dissolved and removed(hereinafter, referred to as “film removal”) using a cotton swabimpregnated with a solvent (acetone) such that an electrode lead-outportion protruding in a convex shape was provided.

[Second Lamination Step D]

One end of the upper electrode laminated body having the same size asthe lower electrode laminated body was cut to provide a portionprotruding in a convex shape in the surface direction, the upperelectrode laminated body was then placed on the laminated body of thelower electrode laminated body and the piezoelectric layer, and theresultant was subjected to thermal compression bonding at 120° C. byusing the laminator device such that the piezoelectric layer and theupper thin film electrode were adhered to each other and a conversionfilm was prepared. The upper electrode laminated body was laminated suchthat the portion of the upper electrode laminated body protruding in aconvex shape (electrode lead-out portion) did not overlap thepiezoelectric layer and did not overlap the portion of the lowerelectrode laminated body protruding in a convex shape.

The wire 36 was connected to each of the electrode lead-out portion ofthe lower thin film electrode 14 and the electrode lead-out portion ofthe upper thin film electrode 16.

Comparative Example 2

A conversion film was prepared in the same manner as in Example 1 exceptthat a lamination step E described below was performed instead of thefirst lamination step A and the second lamination step A.

[Lamination Step E]

The coating material A was applied to the entire surface of the lowerthin film electrode of the lower electrode laminated body and wasthereafter heated and dried on the hot plate at 120° C. such that DMFwas evaporated, thereby preparing a laminated body in which the lowerthin film electrode was formed on the lower protective layer and thepiezoelectric layer having a thickness of 40 μm was formed thereon.

The laminated body was subjected to the polarization processing, theupper electrode laminated body having the same size as the lowerelectrode laminated body was placed on the piezoelectric layer, and theresultant was subjected to thermal compression bonding at 120° C. byusing the laminator device such that the piezoelectric layer and theupper thin film electrode were adhered to each other.

Next, portions of the lower protective layer and the upper protectivelayer were dissolved and removed through laser processing to exposeportions of the lower thin film electrode and the upper thin filmelectrode to the surface, thereby preparing a conversion film. Theexposed portions were used as electrode lead-out portions.

The wire 36 was connected to each of the electrode lead-out portion ofthe lower thin film electrode 14 and the electrode lead-out portion ofthe upper thin film electrode 16.

Comparative Example 3

A conversion film was prepared in the same manner as in Example 1 exceptthat a lamination step F described below was performed instead of thefirst lamination step A and the second lamination step A.

[Lamination Step F]

The coating material A was applied to the entire surface of the lowerthin film electrode of the lower electrode laminated body and wasthereafter heated and dried on the hot plate at 120° C. such that DMFwas evaporated, thereby preparing a laminated body in which the lowerthin film electrode was formed on the lower protective layer and thepiezoelectric layer having a thickness of 40 μm was formed thereon.

The laminated body was subjected to the polarization processing, theupper electrode laminated body having the same size as the lowerelectrode laminated body was placed on the piezoelectric layer, and theresultant was subjected to thermal compression bonding at 120° C. byusing the laminator device such that the piezoelectric layer and theupper thin film electrode were adhered to each other.

Next, portions of the lower protective layer and the upper protectivelayer were cut and removed through machining to expose portions of thelower thin film electrode and the upper thin film electrode to thesurface, thereby preparing a conversion film. The exposed portions wereused as electrode lead-out portions.

The wire 36 was connected to each of the electrode lead-out portion ofthe lower thin film electrode 14 and the electrode lead-out portion ofthe upper thin film electrode 16.

Comparative Example 4

A conversion film was prepared in the same manner as in Example 1 exceptthat a lamination step G described below was performed instead of thefirst lamination step A and the second lamination step A.

[Lamination Step G]

The coating material A was applied to the entire surface of the lowerthin film electrode of the lower electrode laminated body and wasthereafter heated and dried on the hot plate at 120° C. such that DMFwas evaporated, thereby preparing a laminated body in which the lowerthin film electrode was formed on the lower protective layer and thepiezoelectric layer having a thickness of 40 μm was formed thereon.

The laminated body was subjected to the polarization processing, theupper electrode laminated body having the same size as the lowerelectrode laminated body was placed on the piezoelectric layer, and theresultant was subjected to thermal compression bonding at 120° C. byusing the laminator device such that the piezoelectric layer and theupper thin film electrode were adhered to each other.

Next, portions of the piezoelectric layer were dissolved and removedfrom the side surfaces thereof using a cotton swab impregnated with asolvent (acetone) such that electrode lead-out portions were provided.

The wire 36 was connected to each of the electrode lead-out portion ofthe lower thin film electrode 14 and the electrode lead-out portion ofthe upper thin film electrode 16.

Comparative Examples 5 to 8

Conversion films were prepared respectively in the same manners as inComparative Examples 1 to 4 except that the material of thepiezoelectric layer was the same as in Example 4.

Comparative Examples 9 to 12

Conversion films were prepared respectively in the same manners as inComparative Examples 1 to 4 except that the material of thepiezoelectric layer was the same as in Example 7.

[Evaluation]

[Number of Operations]

The number of operations was evaluated according to whether or not therewas an operation aimed only to form the electrode lead-out portion.

A case where there was the operation aimed only to form the electrodelead-out portion was absent was evaluated as A, and A case where theoperation was present was evaluated as B.

[Yield]

The electrostatic capacitance of the prepared conversion film web(conversion film) was measured and the yield was evaluated.

Measurement conditions were set to a measurement frequency of 1 kHz andan execution voltage of 5V, and the electrostatic capacitance wasmeasured in an environment at a temperature of 25° C. and a humidity of40% to 50%.

Measurement was performed on ten test pieces. A case where the number oftest pieces having an electrostatic capacitance of 1.8 to 2.2 μF was 10was evaluated as A, a case where the number of test pieces having anelectrostatic capacitance of 1.8 to 2.2 μF was 9 was evaluated as B, anda case where the number of test pieces having an electrostaticcapacitance of 1.8 to 2.2 μF was 8 or less was evaluated as C.

It is thought that the electrode lead-out portion of the conversion filmweb (conversion film) of which the electrostatic capacitance was outsidethe range was damaged and connection to the wire had failed.

Evaluation results are shown in Table 1.

TABLE 1 Evaluation Piezoelectric layer Forming method of electrodelead-out portion Number of Material Lower portion Upper portionoperations Yield Example 1 Polymer composite piezoelectric bodyFormation of coating material Formation of adhesive non-coated portion AA non-coated portion Example 2 Polymer composite piezoelectric bodyFormation of coating material Formation of non-adhered portion A Anon-coated portion Example 3 Polymer composite piezoelectric bodyFormation of coating material Masking A A non-coated portion Example 4PVDF Formation of coating material Formation of adhesive non-coatedportion A A non-coated portion Example 5 PVDF Formation of coatingmaterial Formation of non-adhered portion A A non-coated portion Example6 PVDF Formation of coating material Masking A A non-coated portionExample 7 Highly dielectric polymer Formation of coating materialFormation of adhesive non-coated portion A A non-coated portion Example8 Highly dielectric polymer Formation of coating material Formation ofnon-adhered portion A A non-coated portion Example 9 Highly dielectricpolymer Formation of coating material Masking A A non-coated portionComparative Polymer composite piezoelectric body Film removal Formationof protruding portion B B Example 1 Comparative Polymer compositepiezoelectric body Laser processing Laser processing B B Example 2Comparative Polymer composite piezoelectric body Machining Machining B CExample 3 Comparative Polymer composite piezoelectric body Film removalfrom side surface Film removal from side surface B C Example 4Comparative PVDF Film removal Formation of protruding portion B BExample 5 Comparative PVDF Laser processing Laser processing B B Example6 Comparative PVDF Machining Machining B C Example 7 Comparative PVDFFilm removal from side surface Film removal from side surface B CExample 8 Comparative Highly dielectric polymer Film removal Formationof protruding portion B B Example 9 Comparative Highly dielectricpolymer Laser processing Laser processing B B Example 10 ComparativeHighly dielectric polymer Machining Machining B C Example 11 ComparativeHighly dielectric polymer Film removal from side surface Film removalfrom side surface B C Example 12

From Table 1, in Examples 1 to 9 as the manufacturing methods of thepresent invention, in the case where the piezoelectric layer and theelectrode laminated body were laminated, the non-adhered portion servingas the electrode lead-out portions were provided. Therefore, there is noneed to provide the operation aimed only to form the electrode lead-outportion, and the number of operations is smaller than in ComparativeExamples 1 to 12.

Therefore, costs can be reduced.

In addition, in the conversion film webs prepared in Examples 1 to 9 asthe manufacturing methods of the present invention, in the case wherethe piezoelectric layer and the electrode laminated body were laminated,the non-adhered portion serving as the electrode lead-out portions wereprovided. Therefore, the yield can be improved compared to ComparativeExamples 1 to 12 without damage to the thin film electrode.

From the above results, the effect of the present invention is obvious.

EXPLANATION OF REFERENCES

10, 10 b: electroacoustic conversion film web

11 a: lower electrode laminated body

11 b: laminated body

11 c: upper electrode laminated body

12: piezoelectric layer

12 a: upper surface

14, 14 b: lower thin film electrode

15, 17: adhesive layer

16: upper thin film electrode

18, 18 b: lower protective layer

20: upper protective layer

24: matrix

26: piezoelectric body particles

30: corona electrode

32: direct-current power source

36: wire

40: piezoelectric speaker

42: case

44: electroacoustic conversion film

46: elastic supporter

48: frame

What is claimed is:
 1. A manufacturing method of an electroacoustic conversion film web including a piezoelectric layer having dielectric properties, two thin film electrodes respectively formed on both surfaces of the piezoelectric layer, and two protective layers respectively formed on the two thin film electrodes, the method comprising: a preparation step of preparing an electrode laminated body in which one of the thin film electrodes and one of the protective layers are laminated; and a lamination step of laminating the electrode laminated body and the piezoelectric layer, wherein, in the lamination step, in a case where the electrode laminated body and the piezoelectric layer are laminated, at least one end portion of the thin film electrode is provided with a non-adhered portion that is not adhered to the piezoelectric layer, the lamination step is a first lamination step of forming the piezoelectric layer by applying a coating composition that is to become the piezoelectric layer onto the thin film electrode of the electrode laminated body and thereafter curing the coating composition, and laminating the electrode laminated body and the piezoelectric layer, and in the first lamination step, in a case where the coating composition is applied, the non-adhered portion is formed by causing the at least one end portion of the thin film electrode to be a coating material non-coated portion to which the coating composition is not applied.
 2. The manufacturing method of an electroacoustic conversion film web according to claim 1, wherein a width of the non-adhered portion is 5 to 20 mm.
 3. The manufacturing method of an electroacoustic conversion film web according to claim 1, wherein a shape of a principal surface of the thin film electrode is a quadrangular shape, and end portions of two edges of the thin film electrode which oppose each other serve as the non-adhered portions.
 4. The manufacturing method of an electroacoustic conversion film web according to claim 1, wherein a thickness of the electrode laminated body is 4 to 20 μm.
 5. The manufacturing method of an electroacoustic conversion film web according to claim 1, wherein the piezoelectric layer is a polymer composite piezoelectric body in which piezoelectric body particles are dispersed in a viscoelastic matrix formed of a polymer material having viscoelasticity at a normal temperature.
 6. The manufacturing method of an electroacoustic conversion film web according to claim 5, wherein a local maximum value at which a loss tangent Tans at a frequency of 1 Hz becomes greater than or equal to 0.5 due to measurement of a dynamic viscoelasticity of the polymer material is present in a temperature range of 0° C. to 50° C.
 7. The manufacturing method of an electroacoustic conversion film web according to claim 5, wherein the polymer material has a cyanoethyl group.
 8. The manufacturing method of an electroacoustic conversion film web according to claim 5, wherein the polymer material is cyanoethylated polyvinyl alcohol.
 9. A manufacturing method of an electroacoustic conversion film web including a piezoelectric layer having dielectric properties, two thin film electrodes respectively formed on both surfaces of the piezoelectric layer, and two protective layers respectively formed on the two thin film electrodes, the method comprising: a preparation step of preparing an electrode laminated body in which one of the thin film electrodes and one of the protective layers are laminated; and a lamination step of laminating the electrode laminated body and the piezoelectric layer, wherein, in the lamination step, in a case where the electrode laminated body and the piezoelectric layer are laminated, at least one end portion of the thin film electrode is provided with a non-adhered portion that is not adhered to the piezoelectric layer, the lamination step is a second lamination step of laminating the electrode laminated body and the piezoelectric layer by bonding the piezoelectric layer to the thin film electrode side of the electrode laminated body, in the second lamination step, the non-adhered portion is formed by causing the at least one end portion of the thin film electrode to be a non-bonded portion to which the piezoelectric layer is not bonded, in a view in a direction perpendicular to the principal surface of the piezoelectric layer, an area of at least one of the two thin film electrodes is smaller than an area of the piezoelectric layer, and in a view in a direction perpendicular to the principal surface of the piezoelectric layer, the at least one of the two thin film electrodes is disposed so as to be included in the piezoelectric layer.
 10. The manufacturing method of an electroacoustic conversion film web according to claim 9, wherein the second lamination step includes an adhesive application step of applying an adhesive to the thin film electrode side of the electrode laminated body, and a bonding step of bonding the piezoelectric layer to the electrode laminated body via the adhesive, and in the adhesive application step, the non-adhered portion is formed by causing the at least one end portion of the thin film electrode to be an adhesive non-coated portion to which the adhesive is not applied.
 11. The manufacturing method of an electroacoustic conversion film web according to claim 9, wherein the second lamination step is to bond the piezoelectric layer to the electrode laminated body through compression bonding, and the non-adhered portion is formed by causing the at least one end portion of the thin film electrode to be a non-compression-bonded portion to which the piezoelectric layer is not compression-bonded.
 12. The manufacturing method of an electroacoustic conversion film web according to claim 9, wherein, in the second lamination step, the non-adhered portion is formed by masking the at least one end portion of the thin film electrode and bonding the piezoelectric layer to the electrode laminated body.
 13. The manufacturing method of an electroacoustic conversion film web according to claim 9, wherein, in the second lamination step, an area of the thin film electrode laminated on the piezoelectric layer in a view in a direction perpendicular to a principal surface of the piezoelectric layer is smaller than an area of the piezoelectric layer.
 14. A manufacturing method of an electroacoustic conversion film web including a piezoelectric layer having dielectric properties, two thin film electrodes respectively formed on both surfaces of the piezoelectric layer, and two protective layers respectively formed on the two thin film electrodes, the method comprising: a preparation step of preparing an electrode laminated body in which one of the thin film electrodes and one of the protective layers are laminated; and a lamination step of laminating the electrode laminated body and the piezoelectric layer, wherein, in the lamination step, in a case where the electrode laminated body and the piezoelectric layer are laminated, at least one end portion of the thin film electrode is provided with a non-adhered portion that is not adhered to the piezoelectric layer, the preparation step is a step of preparing two electrode laminated bodies having different sizes, the lamination step includes a first lamination step of forming the piezoelectric layer by applying a coating composition that is to become the piezoelectric layer onto the thin film electrode of the electrode laminated body having a larger size and thereafter curing the coating composition, and laminating the electrode laminated body having the larger size and the piezoelectric layer, and a second lamination step of laminating the electrode laminated body having a smaller size and the piezoelectric layer by bonding the thin film electrode side of the electrode laminated body having the smaller size to the surface of the piezoelectric layer on the opposite side to the surface on which the electrode laminated body having the larger size is laminated, the electrode laminated body having the larger size being laminated on the piezoelectric layer, in the first lamination step, in a case where the coating composition is applied, the non-adhered portion is formed by causing the at least one end portion of the thin film electrode to be a coating material non-coated portion to which the coating composition is not applied, and in the second lamination step, the non-adhered portion is formed by causing the at least one end portion of the thin film electrode to be a non-bonded portion to which the piezoelectric layer is not bonded.
 15. A manufacturing method of an electroacoustic conversion film, comprising: a cutting step of cutting the electroacoustic conversion film web prepared in the manufacturing method of an electroacoustic conversion film web according to claim 1, into a predetermined shape, wherein, in the cutting step, the electroacoustic conversion film web is cut into a shape in which at least a portion of the non-adhered portion of the thin film electrode remains. 